VESPA S 2012 Service Station Manual Download

Page: 14 / 251

Assembly clearances

Cylinder - piston assy.

CYLINDER - PISTON (125)

Specification

Desc./Quantity

Piston diameter

51.961 (±0.014) mm

Cylinder diameter

52 (+0.008 -0.020) mm

CYLINDER - PISTON (150)

Specification

Desc./Quantity

Piston diameter

57.947 (± 0.014) mm

Cylinder diameter

58 (+0.008 -0.020) mm

COUPLING CATEGORIES (125)

Name

Initials

Cylinder

Piston

Play on fitting

cylinder-piston

51.980 to 51.987

51.947 to 51.954

0.026 ÷ 0.040

cylinder-piston

51.987 to 51.994

51.954 to 51.961

0.026 ÷ 0.040

cylinder-piston

51.994 to 52.001

51.961 to 51.968

0.026 ÷ 0.040

cylinder-piston

52.001 to 52.008

51.968 ÷ 51.975

0.026 ÷ 0.040

COUPLING CATEGORIES (150)

Name

Initials

Cylinder

Piston

Play on fitting

cylinder-piston

57.980 to 57.987

57.933 to 57.940

0.040 to 0.054

cylinder-piston

57.987 to 57.994

57.940 to 57.947

0.040 to 0.054

cylinder-piston

57.994 to 58.001

57.947 to 57.954

0.040 to 0.054

cylinder-piston

58.001 to 58.008

58.954 to 58.961

0.040 to 0.054

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.

Characteristics

Vespa LX - S 125 3V ie 150 3V ie (2012)

CHAR - 14

Summary of Contents for S 2012

Page 1: ...SERVICE STATION MANUAL 677662 EN Vespa LX S 125 3V ie 150 3V ie 2012 ...

Page 2: ... 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 each model should be checked at the official Piaggio sales network Copyright 2013 PIAGGIO VIỆT NAM All rights reserved Reproduction of this publication in whole or in part is prohibi...

Page 3: ... advisable to read the sections of this manual concerning 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 c...

Page 4: ......

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

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

Page 7: ...h a way that 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 se...

Page 8: ...Specification Desc Quantity Chassis prefix 125 ZAPM68301 10000001 Engine prefix 125 M669M 1001 Chassis prefix 150 ZAPM68401 10000001 Engine prefix 150 M66AM 1001 Chassis number The chassis number A is stamped near the bat tery compartment To read it proceed as follows lift the saddle lift the helmet compartment by removing it Engine number The engine number B is stamped near the rear left shock ab...

Page 9: ...THE FOLLOWING INDICACTIONS REFER TO THE S VERSION Vespa LX S 125 3V ie 150 3V ie 2012 Characteristics CHAR 9 ...

Page 10: ...ompliance EURO 3 150 CM ENGINE SPECIFICATIONS Specification Desc Quantity Type Single cylinder 4 stroke Engine capacity 154 8 cm Bore x stroke 58 0 x 58 6 mm Max power 8 7 kW at 7500 rpm MAX torque 12 Nm at 5000 rpm Compression ratio 10 5 1 Idle speed 1750 50 rpm Valve clearance cold engine intake 0 08 mm exhaust 0 08 mm Timing system 3 valves 2 intake 1 drainage single overhead camshaft chain dri...

Page 11: ...nforcements Front suspension Single arm with helical spring and single double acting hy draulic shock absorber Rear suspension Double acting shock absorber adjustable to four positions at preloading Brakes BRAKES Specification Desc Quantity Front brake Ø 200 mm disc brake with hydraulic control activated by han dlebar right side lever Rear brake Ø 110 mm drum brake with mechanical control activate...

Page 12: ...k MUFFLER Name Torque in Nm Silencer heat guard fixing screw 4 to 5 Screws fixing silencer to the crankcase 24 27 Lambda probe tightening on exhaust manifold 40 to 50 FRONT SUSPENSION Name Torque in Nm Shock absorber upper nut 20 to 30 Front wheel axle nut 75 to 90 Shock absorber upper bracket bolts 20 to 25 Wheel screw 20 to 25 Shock absorber lower bolts 20 to 27 Apply LOCTITE 242 threadlock REAR...

Page 13: ...ting See section ENGINE LUBRICATION STUD BOLT Throttle body clamp screws 1 3 to 1 7 Tensioner spring retaining screw 5 to 6 Fastener chain tensioner 11 to 13 Thermostat cover screws 3 4 Pressure reducer counterweight retainer screw 7 to 8 5 Injection manifold fixing screws 11 to 13 Valve clearance adjustment screw 6 to 9 Spark plug tightening 10 to 12 Timing system sprocket fixing screw 4 to 6 Scr...

Page 14: ...piston C 51 994 to 52 001 51 961 to 51 968 0 026 0 040 cylinder piston D 52 001 to 52 008 51 968 51 975 0 026 0 040 COUPLING CATEGORIES 150 Name Initials Cylinder Piston Play on fitting cylinder piston A 57 980 to 57 987 57 933 to 57 940 0 040 to 0 054 cylinder piston B 57 987 to 57 994 57 940 to 57 947 0 040 to 0 054 cylinder piston C 57 994 to 58 001 57 947 to 57 954 0 040 to 0 054 cylinder pist...

Page 15: ...on mounting A of the bands N B MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE SECOND SEAL RING SIDE ASSEMBLY CLEARANCE OF BANDS SEAL RINGS 125 DESIGNATION SIZES ASSEMBLY CLEARANCES A 1 compression ring mm 52x0 8 0 20 to 0 35 2 compression ring mm 52x1 0 0 20 to 0 45 Oil ring segments mm 52x2 0 0 25 to 0 55 ASSEMBLY CLEARANCE OF BANDS SEAL RINGS 150 DESIGNATION SIZES ASSE...

Page 16: ...ting rod Axial clearance between crankshaft and connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Code Sizes Assembly clearance Half shaft transmission side A 18 1 0 0 05 mm D 0 20 0 50 Flywheel side half shaft B 18 1 0 0 05 mm D 0 20 0 50 Connecting rod C 15 0 10 0 15 mm D 0 20 0 50 Spacer tool E 51 4 0 0 05 mm D 0 20 0 50 Diameter of crankshaft bearings Measure the bearin...

Page 17: ...iameter Cat 2 27 004 to 27 010 mm To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and a good oil flow rate the bushings must be correctly positioned so as not to obstruct the oil supply channels Characteristic A AXIS CYLINDER Vespa LX S 125 3V ie 150 3V ie 2012 Characteristics CHAR 17 ...

Page 18: ...pposite 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 photo Characteristic A AXIS CYLINDER BUSHINGS TYPE IDENTIFICATION CRANKSHAFT HALF BEARING B BLUE 1 971 to 1 976 C YELLOW 1 974 to 1 979 E GREEN 1 977 to 1 982 Characteristics Vespa LX S 125 3V ie 150 3V ie 2012 CHAR 18 ...

Page 19: ...r using a bore meter at two depths indicated in the figure the diameter of the bushings After measuring the two diameters take the average Characteristic A AXIS CYLINDER The bushings housing hole in the crankcase half is divided into two categories depending on the size Category 1 and Category 2 DIAMETER OF CRANKCASE WITHOUT BUSHING Specification Desc Quantity CAT 1 30 959 to 30 965 mm CAT 2 30 95...

Page 20: ... coupling surfaces Note the position of the springs and the valves so as not to change the original position during refitting Using a trued bar and a feeler gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum allowable run out 0 03 mm In case of faults replace the head Check the sealing surfaces for the exhaust manifold Check that the camshaft and the rocking...

Page 21: ... 8 mm Remove any carbon deposits from the valve seats Check the width of the mark on the valve seat V with Prussian blue Characteristic Standard value 1 1 3 mm If the width of the mark on the valve seat is larger than the prescribed limits true the seats with a 45 milling cutter and then grind In case of excessive wear or damage replace the head Vespa LX S 125 3V ie 150 3V ie 2012 Characteristics ...

Page 22: ...he valve stem by resting it on a V shaped support and measuring the ex tent of the deformation using a dial gauge Characteristic Limit values admitted 0 02 mm Check the oscillation of the valve head by ar ranging a dial gauge at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 3 mm Measure the valve guide Characteristic Valve guide 4 3 0...

Page 23: ...he valves gently with a fine grained lapping compound During the grinding keep the cylinder head with the valve axes in a horizontal position This will prevent the lapping compound residues from penetrating between the valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND ...

Page 24: ...ver pins do not show signs of wear or scoring Measure the internal diameter of each rocker Check there are no signs of wear on the slider from contact with the cam and on the jointed adjustment plate ROCKING LEVERS AND PIN DIAMETER Specification Desc Quantity Rocking lever inside diameter Standard diameter C Ø 10 015 to 10 035 mm Rocking lever pin diameter Standard diameter D Ø 10 015 to 10 023 mm...

Page 25: ...side the cylinder the less the base gasket to be applied to recover the compression ratio and vice versa N B MEASUREMENT A MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK CASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE EQUIPPED WITH A SUP PORT ON A GROUND PLANE ENGINE 125 150 SHIMMING Name Measure A Thickness Shimming 0 to 0 1 0 8 0 05 Shimming 0 1 to 0 3 0 6 0 05 Shimming 0 3 to 0 ...

Page 26: ...ISO L X BCHA 3 DIN 51 825 K3K 20 AGIP GP 330 Water repellent stringy calcium spray grease R I D A D R 2 10 b 2 R I Na 2 42 I A T A 2 I M D G class 2 UN 1950 Page 9022 EM 25 89 UNIT OF MEASURE CONVERSION ENGLISH SYSTEM TO INTERNATIONAL SYSTEM IS Specification Desc Quantity 1 Inch in 25 4 Millimetres mm 1 Foot ft 0 305 Meter m 1 Mile mi 1 609 Kilometre km 1 US Gallon USgal 3 785 Litre l 1 Pound lb 0...

Page 27: ...INDEX OF TOPICS TOOLING TOOL ...

Page 28: ...Y008 Pliers to extract 17 mm ø bearings 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract ø 15 mm bearings 002465Y Calliper for circlips 005095Y Engine support 006029Y Punch for fitting steering bearing seat on steering tube Tooling Vespa LX S 125 3V ie 150 3V ie 2012 TOOL 28 ...

Page 29: ...code Description 020004Y Punch for removing steering bearings from headstock 020021Y Front suspension service tool 020036Y Punch 020037Y Punch 020038Y Punch Vespa LX S 125 3V ie 150 3V ie 2012 Tooling TOOL 29 ...

Page 30: ...teering tube ring nut 020074Y Support base for checking crankshaft alignment 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge 020263Y Driven pulley assembly sheath Tooling Vespa LX S 125 3V ie 150 3V ie 2012 TOOL 30 ...

Page 31: ...20325Y Pliers for brake shoe springs 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator Vespa LX S 125 3V ie 150 3V ie 2012 Tooling TOOL 31 ...

Page 32: ...ple battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35 mm Adaptor 020358Y 37x40 mm Adaptor 020359Y 42 x 47 mm Adaptor 020360Y 52 x 55 mm Adaptor 020363Y 20 mm guide Tooling Vespa LX S 125 3V ie 150 3V ie 2012 TOOL 32 ...

Page 33: ...ide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Tool to extract valve cotters 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork Vespa LX S 125 3V ie 150 3V ie 2012 Tooling TOOL 33 ...

Page 34: ...020427Y Piston assembly band 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020441Y 26 x 28 mm adaptor 020444Y011 adapter ring 020444Y009 wrench 46 x 55 Tooling Vespa LX S 125 3V ie 150 3V ie 2012 TOOL 34 ...

Page 35: ...20442Y Pulley lock wrench 020444Y Tool for fitting removing the driven pulley clutch 020480Y Petrol pressure check kit 020922Y Diagnosis Tool 020933Y Flywheel extractor 020937Y Driven pulley lock Vespa LX S 125 3V ie 150 3V ie 2012 Tooling TOOL 35 ...

Page 36: ...res code Description 020938Y Driving pulley lock 020939Y Flywheel retainer 020941Y Crankshaft timing adjustment tool 020942Y Piston protrusion check tool Tooling Vespa LX S 125 3V ie 150 3V ie 2012 TOOL 36 ...

Page 37: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 38: ...er housing I I Air filter I I Engine oil filter R R R Valve clearance A A A Electrical system and battery I I I I I I Cylinder ventilation system Brake levers L L L Brake fluid I I I I I I Engine oil R I R I R I Hub oil I I Headlight direction adjustment A A Brake pads I I I I I I Tyre pressure and wear I I I I I I Vehicle road test I I I I I I Odometer gear L L Suspension I I Steering A A A Trans...

Page 39: ...aly as described before replace the spark plug with another of the recommended type Fit the spark plug with the correct inclination and manually screw it all the way down then use the special spanner to tighten it Fit the cap on the spark plug as far as it will go Carry out refit operations CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD CHECK AND REPLACE THE SPARK PLUG AS INDICATED...

Page 40: ...comes out of the screw hole the oil quantity in the hub is adequate place it and tighten the screw oil does NOT come out of the screw hole the oil quantity in the hub IS NOT adequate and it is necessary to carry out the top up With a cloth carefully clean the transmission crankcase Replacement Remove the oil level check and filler screw Maintenance Vespa LX S 125 3V ie 150 3V ie 2012 MAIN 40 ...

Page 41: ...d products AGIP GEAR SAE 80W 90 Lubricant for gearboxes and transmissions API GL 4 Characteristic Rear hub oil 200 cm Locking torques N m Hub oil drainage screw 15 to 17 Air filter Remove the helmet compartment Disconnect the air intake pipe from the filter box Undo the indicated fixing screws Remove the left side fairing Vespa LX S 125 3V ie 150 3V ie 2012 Maintenance MAIN 41 ...

Page 42: ... engines the engine oil is used to lubricate the timing elements the bench bearings and the thermal group An insufficient quantity of oil can cause serious damage to the engine In all four stroke engines the deterioration of the oil characteristics or a certain consumption should be considered normal especially if during the run in period Consumption levels in particular can be influenced by the c...

Page 43: ...anging purposes N B THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED Recommended products eni i Ride PG 10W 40 Synthetic based lubri cant for four stroke engines JASO MA MA2 API SL ACEA A3 Check This operation must be carried out with the engine cold and following the procedure below Place the vehicle on its centre stand and on flat ground Undo cap dipstick dry it off with a clean cloth and reinsert...

Page 44: ...o the specified torque Refit the new cartridge filter being careful to lubricate the O ring before fitting it Change the engine oil Recommended products eni i Ride PG 10W 40 Synthetic based lubricant for four stroke engines JASO MA MA2 API SL ACEA A3 Oil pressure warning light The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the ON position Ho...

Page 45: ...HE COR RECT FITTING OF COMPONENTS Checking the valve clearance To check valve clearance centre the reference marks of the timing system Use a feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values When the valve clear ance values intake and exhaust respectively are different from the ones indicated below adjust them by loosening the lock n...

Page 46: ...F ACCIDENTAL CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS CAUTION BRAKE FLUID IS HYGROSCOPIC THAT IS IT ABSORBS MOISTURE FROM THE SURROUNDING AIR IF THE CON TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEFFICIENT NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS UNDER NORMAL C...

Page 47: ...en situated in a shaded area making sure that the longitudinal axis of the vehicle is perpendicular to the screen 2 Turn on the headlight and check that the bor derline of the projected light beam on the screen is no higher than 9 10 or lower than 7 10 of the distance from the ground to the centre of the ve hicle s headlamp 3 If otherwise adjust the right headlight with screw A Vespa LX S 125 3V i...

Page 48: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 49: ...ows signs of sulphation replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1 10 of the capacity of the battery itself Faulty spark plug Replace the spark plug Incorrect valve sealing or valve adjustment Inspect the head and or restore the correct clearance Starter motor and start up system fault Check starter motor Altered fuel characterist...

Page 50: ...e 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 Carefully bleed the hydraulic braking system there must be no flexible movement of the brake lever Fluid leakage in ...

Page 51: ...ents check the seats in which the ball bearings rotate if they are recessed or if the balls are squashed replace them Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering clearance Check the tightening of the top ring nut If irregularities continue in turning the steering even after making the above adjust ments check the seats in which the ball bearings...

Page 52: ...Troubleshooting Vespa LX S 125 3V ie 150 3V ie 2012 TROUBL 52 ...

Page 53: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 54: ... LX VERSION S VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 54 ...

Page 55: ...ylight running light bulbs and license plate light 7 Headlight with twin filament bulb 8 Light switch 9 Headlight relay 10 Stop buttons 11 Fuses No 3 4 6 12 Light switch 13 Fuse No 5 14 Fuse No 2 15 Ignition switch 16 Starter motor 17 Starter remote control switch 18 Fuse No 1 Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 55 ...

Page 56: ... socket 30 Injector 31 Engine temperature sensor 32 Fuel pump 33 Side stand switch 34 Electronic control unit 35 Immobilizer Aerial 36 Fuel level transmitter 37 Oil pressure sensor KEY Ar Orange Az Light blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Components arrangement Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 56 ...

Page 57: ...ov er as described in the Engine chapter to reach it To get access to the connectors remove the helmet compartment 2 Voltage regulator Remove the front central cover to reach it Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 57 ...

Page 58: ... the cover to reach them 4 Starter remote control Remove the battery to reach it 7 8 14 15 16 26 Fuses Remove the battery cover and or the front central cover to reach them Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 58 ...

Page 59: ...ransmitter They are fitted on the tank remove the fuel tank to reach them 25 Oil pressure sensor To access remove the fan cover cap as described in the ENGINE chap ter 27 Immobilizer aerial Remove the shield back plate to reach it Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 59 ...

Page 60: ... Remove the helmet compartment to reach it 31 32 Engine temperature sensor fuel injec tor Remove the helmet compartment to reach it 33 H V coil Remove the helmet compartment and undo the two screws indicated to reach it Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 60 ...

Page 61: ...and Ground points On the vehicle there is a chassis ground point marked with letter A on the right side of the bat tery compartment There is another ground point B on the starter motor Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 61 ...

Page 62: ...he chassis under the footrest there is the chassis engine ground lead C Electrical system installation Front side 1 Fuse boxes 2 Turn indicator control device Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 62 ...

Page 63: ...er antenna 6 Front left turn indicator 7 Front right turn indicator 8 Voltage regulator 9 Connection cables injection load relays and lighting 10 Voltage regulator connection Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 63 ...

Page 64: ...11 Connecting branch controls on the driver and the front headlights 12 On connecting branch rear part of the system Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 64 ...

Page 65: ...13 On connecting branch rear part of the system Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 65 ...

Page 66: ...Back side 1 Spark plug cap 2 Connection of pick up sensor 3 Stator connection 4 Diagnostics connection 5 HV coil Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 66 ...

Page 67: ...el level transmitter 7 Connection electronic control unit 8 Injector connection 9 Engine temperature sensor 10 Connections to the battery poles 11 Starter remote control switch Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 67 ...

Page 68: ...12 Chassis ground point 13 Lambda probe cable connector 14 Lambda probe Conceptual diagrams Ignition LX VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 68 ...

Page 69: ... S VERSION Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 69 ...

Page 70: ... No 2 15 Ignition switch 18 Fuse No 1 21 Battery 23 Injection load relay 28 H V coil 34 Electronic control unit 35 Immobilizer Aerial Battery recharge and starting LX VERSION S VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 70 ...

Page 71: ...tarter motor 17 Starter remote control switch 18 Fuse No 1 19 Magneto flywheel 20 Voltage regulator 21 Battery 22 Stop light bulb 34 Electronic control unit Level indicators and enable signals section LX VERSION Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 71 ...

Page 72: ... S VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 72 ...

Page 73: ... load relay 26 Lambda probe 27 Engine speed sensor 30 Injector 31 Engine temperature sensor 33 Side stand switch 34 Electronic control unit 35 Immobilizer Aerial 36 Fuel level transmitter 37 Oil pressure sensor Devices and accessories LX VERSION Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 73 ...

Page 74: ...se No 2 15 Ignition switch 18 Fuse No 1 21 Battery 23 Injection load relay 24 Horn button 25 Horn 32 Fuel pump 34 Electronic control unit Lights and turn indicators LX VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 74 ...

Page 75: ... S VERSION Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 75 ...

Page 76: ... Daylight running light bulbs and license plate light 7 Headlight with twin filament bulb 8 Light switch 9 Headlight relay 11 Fuses No 3 4 6 12 Light switch 13 Fuse No 5 14 Fuse No 2 15 Ignition switch 18 Fuse No 1 21 Battery 34 Electronic control unit INJECTION LX VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 76 ...

Page 77: ...er remote control switch 18 Fuse No 1 21 Battery 23 Injection load relay 26 Lambda probe 27 Engine speed sensor 28 H V coil 29 Diagnostics socket 30 Injector 31 Engine temperature sensor 32 Fuel pump 33 Side stand switch 34 Electronic control unit Vespa LX S 125 3V ie 150 3V ie 2012 Electrical system ELE SYS 77 ...

Page 78: ...tenna master and service keys with built in transponder HV coil diagnosis LED The diagnosis led also works as a blinking light to deter theft This function is activated every time the ignition switch is turned to OFF and it remains active 48 hours so as not to damage the battery charging process When the ignition switch is turned to ON it inter rupts the function of the immobiliser lamp and a star...

Page 79: ...e in working order With the key switch in the ON position there is battery voltage between terminals 6 7 and terminal 6 chassis ground fixed power supply If there is no voltage check the ignition key contacts that fuse 6 and its cable are in working order After removing the leg shield back plate remove the electrical connection from the aerial as shown in the picture Remove the protective base fro...

Page 80: ...ce 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 turn it to ON for 2 seconds The maximum time to change keys is 10 seconds A maximum of 7 service keys can be programmed at one time It is essential to adhere to the times and the pro cedure If you do not start again from the begin ning Once the system has been pro...

Page 81: ...y unused control unit transpond er absent or cannot be used the LED is on permanently In this condition no operations are possible including the start up of the vehicle 3 Programmed control unit the service key in normal condition of use a single 0 7 second flash is displayed after which the LED remains off steadily The engine can be started 4 Programmed control unit Master key in a 0 7 sec flash ...

Page 82: ...er Turn the switch to ON using several keys if the code is repeated even with the Master key check the aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Diagnostic code 3 flashes A three flash code indicates a system where the control unit does not recognise the key Turn the...

Page 83: ...hree yellow cables as shown in the picture 3 Measure the resistance between each of the yellow terminals and the other two Electric characteristic Resistance 0 2 1 Ω 4 Check that there is insulation between the each yellow cable and the ground 5 If values are incorrect replace the stator Recharge system voltage check Look for any leakage 1 Access the battery by removing the specific cover 2 Check ...

Page 84: ...d 15 0V at 5000 rpm Maximum current output check With engine off and panel set to ON turn on the lights and let the battery voltage set to 12V Connect ammeter pliers to the 2 recharge positive poles in output from the regulator Keep the lights on and start the engine bring it to normal speed and read the values on the ammeter With an efficient battery a value must be detected 20A VOLTAGE REGULATOR...

Page 85: ...utton 4 Check with the ignition switch ON brake engaged and start button pressed the presence of voltage between the White Black cable of the starter relay and ground otherwise check the cable harness 5 Check the starter relay 6 Check that the Red cable between the battery and the starter relay is not interrupted Also check continuity between the latter and the starter motor 7 Check the starter mo...

Page 86: ...ED 1 Check fuses No 1 and 3 2 Check the ignition switch and horn button contacts 3 With the ignition switch set to ON and the horn button pressed check if there is voltage between the Grey Black cable of the horn device and the ground connection If there is not check the cable harnesses 4 Check the horn device ground connection Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 86 ...

Page 87: ...ack cable of the turn indicators switch and the ground connection If there is not check the cable harnesses and the con nections of the turn indicator control device 5 Check the turn indicator switch contacts 6 With the turn indicator switch pressed to the right check if there is voltage between the White Blue cable of the switch and the ground connection If there is not check the cable harnesses ...

Page 88: ...alues be tween the White Green cable and the Black cable of the fuel level transmitter under different condi tions 2 If the transmitter operates correctly but the in dication on the instrument panel is not exact check that the cable harnesses between them are not interrupted Electric characteristic Resistance value when the tank is full 7 Ω Resistance value when the tank is empty 90 13 3 Ω Lights ...

Page 89: ...ble 6 Check that the cable harnesses of the bulbs and their ground connection are not interrupted HIGH BEAM LOW BEAM LIGHTS LINE 1 Check that bulbs operate properly 2 Check fuses No 1 and 4 3 Check ignition switch contacts 4 Check if there is voltage between the Grey Red cable of the headlight remote control and the ground connection If there is not check cable harnesses 5 With the key switch set ...

Page 90: ...e Incandescent Power 12V 2W Quantity 3 THE FOLLOWING INDICACTIONS REFER TO THE S VERSION BULBS Specification Desc Quantity 1 High low beam light bulb Type Halogen H4 Power 12V 55 60W Quantity 1 2 Front daylight running light bulbs Type Incandescent Power 12V 5W Quantity 1 3 Stop light rear daylight running light bulb Type Incandescent Power 12V 5W 18W Quantity 1 4 License plate bulb Type Incandesc...

Page 91: ...OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE CAUTION MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS TEM PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK OF FIRE MAIN FUSES Specification Desc Quantity Fuse No 1 Capacity 20 A Protected circuits General recharge circuit Fuse No 6 Capacity 10 A Protected circuits Injection...

Page 92: ...tton horn instrument panel Fuse No 4 Capacity 10 A Protected circuits Lowbeam highbeam light switch via relay Fuse No 5 Capacity 7 5 A Protected circuits light switch headlight relay power instru ment panel Dashboard LX VERSION S VERSION Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 92 ...

Page 93: ...nce required is the check of its charge and recharging if necessary These operations should be carried out before delivering the vehicle and on a six month basis while the vehicle is stored in open circuit Besides upon pre delivery it is therefore necessary to check the battery charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE BATTE...

Page 94: ...ERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS IT CONTAINS SUL PHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IN CASE OF CON TACT WITH YOUR EYES OR SKIN RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK MAGNESIUM MILK BATTERED EGG OR VEGETABL...

Page 95: ...les coming out of the filling holes lightly tap the bottom of the container two or three times Do not remove the container from the battery 5 Take out the container Make sure all the electrolyte in the battery is drained Gently tap the bottom of the container if electrolyte remains in the container Now gently pull the container out from the battery only do this when the container is completely emp...

Page 96: ...arge battery MF like the completely loa ded YTX must have a no load voltage between 12 8 13 15 V Bring the battery to full charge us ing the 020648Y battery charger a select the type of battery with the red switch on the left of the panel battery charger panel b select NEW on the yellow timer c connect the clamps of the battery charger to the battery poles black clamp to negative pole and red clam...

Page 97: ... the voltage if voltages are detected of less than 12 8 V proceed with a new recharge of the battery starting from point c of the recharge pro cedure of the new battery otherwise go to point i i The battery is now completely activated disconnect the battery charger from the fuel supply grid disconnect the clamps from the battery and proceed to fitting the battery on the vehicle Vespa LX S 125 3V i...

Page 98: ...ECTOR 1 Not connected 2 Ground lead Black 3 Not connected 4 Not connected 5 Power from relay Black Green ELECTRONIC CONTROL UNIT CONNECTOR 1 H V COIL Pink Black 2 Not connected 3 Not connected 4 Ground Orange 5 Starter button Purple 6 Ignition switched live Orange Blue 7 Ground No 1 Black 8 Not connected 9 Battery power Red White 10 Start up enabling switch Purple White Electrical system Vespa LX ...

Page 99: ...22 Injection load relay Black Purple 23 Ground No 2 Black 24 Not connected 25 Injection warning light Brown White 26 Not connected 27 Not connected 28 Not connected 29 Engine speed sensor positive Red 30 Not connected 31 Lambda probe heater Light blue Red 32 Not connected 33 Low beam lights automatic ignition enabling White Black 34 Fuel injector Red Yellow ENGINE TEMPERATURE SENSOR CONNEC TOR 1 E...

Page 100: ...ater negative from control unit Light blue Red 3 Control unit positive Green Blue 4 Negative from control unit Light blue Black VOLTAGE REGULATOR CONNECTOR 1 Battery positive Red Black 2 Ground lead Black H V COIL CONNECTOR 1 Power from relay Black Green 2 Electronic control unit Pink Black Electrical system Vespa LX S 125 3V ie 150 3V ie 2012 ELE SYS 100 ...

Page 101: ... TO THE LX VERSION INSTRUMENT PANEL CONNECTOR A 1 Live supply White 2 Fuel level indicator White Green 3 Ground lead Black 4 Instrument panel lighting Yellow Black 5 Right indicator warning light White Blue 6 Left indicator warning light Pink INSTRUMENT PANEL CONNECTOR B 1 Low fuel warning light Yellow Green 2 Oil pressure warning light White Pink 3 High beam warning light Purple 4 Injection warni...

Page 102: ...low Black 4 Ground lead Black INSTRUMENT PANEL CONNECTOR B 1 Injection warning light Brown White 2 Live supply White 3 Battery power Red White 4 Immobilizer warning light Yellow INSTRUMENT PANEL CONNECTOR C 1 Battery powered White 2 Low fuel warning light Yellow Green 3 Oil pressure warning light White Pink 4 Fuel level indicator White Green 5 High beam warning lights Purple Diagnostic instrument ...

Page 103: ... is in the cabling or the relay if the short is in the relay ENGINE TEMPERATURE SENSOR Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Pinout 1 Injection ECU 2 Ground from control unit Engine temperature sensor P0115 open circu...

Page 104: ...ts this means that there is a probable fault in the control unit LAMBDA PROBE Function In charge of telling the control unit whether the mixture is lean or rich Operation Operating principle Based on the difference of oxygen in the exhaust fumes and the environment this generates volt age which is read and interpreted by the injection control unit It does not require an external supply source but ...

Page 105: ...r and the control unit connector Check the sensor connector PIN 3 from ground insulation If there is no insulation restore the cable harness Check the sensor connector PIN 4 from ground insulation If there is no insulation restore the cable harness If PIN 3 and PIN 4 are insulated from the ground and the error persists this means that there is a probable fault in the control unit P0135 Lambda prob...

Page 106: ...CTRICAL ERRORS Injector P0201 short circuit to positive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage to PIN 34 of the control unit connector Short circuit to negative zero voltage to the PIN 1 of the injector connector Open circuit circuit interruption Troubleshooting Short circuit to positive Disconnect the injector connector turn ignition switch ...

Page 107: ...86 and 85 toward the cabling If no voltage is read disconnect the control unit and verify insulation from battery positive of the relay PIN 85 or control unit PIN 22 If necessary restore the cable harness Short circuit to negative Disconnect the injection relay and the control unit Verify ground insulation of the relay connector PIN 86 and 85 toward the cabling if there is no insu lation restore t...

Page 108: ...ntrol unit connectors Verify continuity of the cabling between the coil and control unit Coil PIN 2 control unit PIN 1 If there is no continuity restore the cable harness Verify with the key turned ON the presence of voltage on the coil connector PIN 1 If no voltage is detected check that the cable harness between the coil and injection relay is not interrupted Coil PIN 1 relay PIN 30 If the above...

Page 109: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 110: ...nd disconnect it Release the lambda probe cable from the bracket on the fan cover Loosen the 2 exhaust fixing screws to the crank case then remove the whole exhaust Remove the lambda probe from the manifold Removal of the engine from the vehicle CAUTION Engine from vehicle Vespa LX S 125 3V ie 150 3V ie 2012 ENG VE 110 ...

Page 111: ...ake transmission by un screwing the adjuster screw Disconnect the belt cooling pipe and the swinging arm retaining spring shown in the picture Disconnect the ground lead 1 from the engine Disconnect the air intake pipe from the filter box Remove the ground lead and the positive cable from the starter motor shown in the figure Disconnect the cable camp bracket from the throttle body and remove the ...

Page 112: ... en gine temperature sensor Disconnect the two magneto flywheel cable har ness connectors slide them out from the bottom and free the cable tie that joins them to the main cable harness Disconnect the flywheel cables retainer bracket from the engine Engine from vehicle Vespa LX S 125 3V ie 150 3V ie 2012 ENG VE 112 ...

Page 113: ...n the right side unscrew and remove the nut which holds the coupling bolt swinging arm engine Working on the left side remove the bolt be careful to collect the spacer Support the vehicle adequately with a jack and remove the shock absorber lower clamping Vespa LX S 125 3V ie 150 3V ie 2012 Engine from vehicle ENG VE 113 ...

Page 114: ...INDEX OF TOPICS ENGINE ENG ...

Page 115: ...ission Transmission cover Remove the air duct Remove the plastic cover that has the vehicle logo on it Insert the specific tools rotate the engine until the driven pulley stops and remove the nut recovering the washer Specific tooling 020937Y Driven pulley lock Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 115 ...

Page 116: ...n screws fixing the engine and re move the transmission cover See also Air duct Air duct Remove the plastic cover Unscrew the two screws indicated and remove the duct Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 116 ...

Page 117: ...andle 020357Y 32 x 35 mm Adaptor 020412Y 15 mm guide Refitting the driven pulley shaft bearing Use the heat gun to heat the inner part of the lid Using the equipment plant a new bearing apply grease on the adapter and guide in order to main tain the position of the bearing during operation on the vertical axis Specific tooling 020151Y Air heater 020376Y Adaptor handle 020358Y 37x40 mm Adaptor 0204...

Page 118: ...t the alignment dowels if removed during disassembly Removing the driven pulley Undo the clutch fixing screw recovering the lin ing Remove the clutch drum Remove the driven pulley Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 118 ...

Page 119: ... and 17 mm Lock with the original spacer and nut Place the bell shaft unit on the support to check the crankshaft alignment Using a feeler dial gauge and the magnetic base measure the bell eccentricity Repeat the measurement in 3 positions Central internal external If faults are found replace the bell Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting...

Page 120: ...w make contact with a minimum force Using the specific wrench inserted 46 mm from the side remove the clutch central locking nut Separate the components of the driven pulley CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE TIGHTENED WITH EX CESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL Specific tooling 020444Y Tool for fitting removing ...

Page 121: ... mm Pin retaining collar Simultaneously turn and pull the collar manually to remove it N B USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL TY N B BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O RING SEAL Removing the driven half pulley bearing Remove the retainer ring using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as...

Page 122: ...ng the driven half pulley bearing Assemble a new roller bearing using the specific punch fit the bearing with the label facing outward and insert it completely up to the punch on the half pulley N B REST THE HALF PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT Specific tooling 020424Y Driven pulley roller casing fitting punch Engine Vespa LX S ...

Page 123: ...half pulley on the ringlet with the appropriate protection sheath Make sure the pins and collar are not worn re assemble the pins and collar Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole This operation is necessary to avoid the presen...

Page 124: ...teristic Standard length 106 mm Refitting the driven pulley Reassemble the clutch housing and spacer Drive belt Make sure the drive belt is not damaged and does not show abnormal wear Replace as indicated in the scheduled maintenance table Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 124 ...

Page 125: ...pulley and loosen the nut Specific tooling 020938Y Driving pulley lock Remove the flat washer and the cup washer Remove the stationary half pulley and the wash er Disengage the belt Remove the complete roller housing Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 125 ...

Page 126: ... of the roller housings and of the belt faying surfaces on both pulley halves Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS Characteristic Movable driving half pulley bushing Ø30 0 081 0 060 mm Sliding bushing Ø26 0 020 0 041 mm Characteristic CVT rollers ...

Page 127: ...o lock the pulley CAUTION DURING THE INSTALLATION PAY SPECIAL ATTENTION TO THE ASSEMBLY OF THE BELLEVILLE SPRING AS SHOWN IN FIGURE Specific tooling 020938Y Driving pulley lock Locking torques N m Driving pulley retainer nut 75 to 83 Refitting the transmission cover Follow the removal steps but in reverse order be careful to tighten to the prescribed torques Locking torques N m Vespa LX S 125 3V i...

Page 128: ...crew the oil filler screw in order to facilitate bleeding Recommended products AGIP GEAR SAE 80W 90 Lubricant for gear boxes and transmissions API GL 4 Characteristic Hub oil 200 cm Remove the brake shoe Unscrew the eight hub cap fixing screws Remove the final reduction cap complete with the wheel axle being careful not to drop the inter mediate gear Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG ...

Page 129: ...Remove the bearing working from the external side and using the specific tools Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42 x 47 mm Adaptor Removing the intermediate gear bearing Remove the bearing using the specific tools Specific tooling 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract ø 15 mm bear ings Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG ...

Page 130: ...e with the crankcase Remove the Seeger ring from the outside Operating on the inside remove the oil seal Remove the wheel axle bearing using the specific tool Specific tooling 020376Y Adaptor handle 020364Y 25 mm guide 020359Y 42 x 47 mm Adaptor Removing the intermediate gear bearing Using the specific tools remove the bearing Specific tooling 001467Y013 Calliper to extract ø 15 mm bear ings 00146...

Page 131: ...lace the damaged parts Characteristic Driven pulley shaft A 22 0 01 0 02 mm Wheel axle B 15 0 010 0 020 mm C 25 0 007 0 020 mm Intermediate gear D 15 0 01 0 02 mm E 15 0 01 0 02 mm Inspecting the hub cover Check that the fitting surface is not dented or distorted Check the bearing bearings In case of faults replace the damaged components Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 131 ...

Page 132: ... heat the bearing seat Set a new bearing using the specific equipment Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor For main bear ings and wheel axle 020412Y 15 mm guide Fitting the Wheel axle bearing Use the heat gun to heat the bearing seat Set a new bearing using the specific equipment Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 ...

Page 133: ...20151Y Air heater 020376Y Adaptor handle 020360Y 52 x 55 mm Adaptor 020364Y 25 mm guide Fitting the transmission gear bearing Use the heat gun to heat the bearing seat Using the equipment set a new bearing Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor 020412Y 15 mm guide Refitting the hub bearings Insert the gears in the cover in order to prevent abnormal mo...

Page 134: ...he speci fied torque tightening in crossed sequence Check the correct the tightening drainage screw Locking torques N m Hub cover fixing screws 23 53 to 26 48 Reduction unit oil drainage screw 15 to 17 Restore the level of oil inside duction unit with the recommended product acting on the filler screw until touching Tighten to the specified torque Recommended products AGIP GEAR SAE 80W 90 Lubrican...

Page 135: ...ap Cooling fan Remove the front part of the fan unscrewing the three fixing screws Using the specific tool unscrew the cooling fan fixing screw Remove the fan Recover the wrench Specific tooling 020442Y Pulley lock wrench Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 135 ...

Page 136: ...ove the oil dipstick Remove the sensor connector Unscrew the eleven fixing screws of the flywheel cover Remove the cover Remove the gasket Pay attention to the alignment dowels Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 136 ...

Page 137: ...harness Refitting the stator Refit the stator and flywheel carrying out the re moval procedure in reverse tightening the retain ers to the specified torque Respect the operation of the pick up Locking torques N m Stator fixing screws 8 to 10 Pickup fixing screws 3 to 4 Refitting the flywheel cover Fit the gasket and be careful with the two align ment dowels Vespa LX S 125 3V ie 150 3V ie 2012 Engi...

Page 138: ...NING THE FLYWHEEL COVER Specific tooling 020940Y Flywheel cover oil seal gasket FLYWHEEL COVER SCREWS POSITION SIZES TORQUE Nm A M6x90 11 to 13 B M6x35 11 to 13 C M6x30 11 to 13 Flywheel and starting Removing the starter motor Undo the two fixing screws and remove the start er motor Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 138 ...

Page 139: ...e washer Specific tooling 020939Y Flywheel retainer Before screwing in the flywheel extractor the pro tection tool provided in the specific tool must be positioned Specific tooling 020933Y Flywheel extractor Acting on the extractor remove the flywheel to gether with the starting sprocket and intermediate gear Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 139 ...

Page 140: ...flywheel magneto Perform the procedure in reverse order of disassembly taking care to tighten to specified torque Locking torques N m Flywheel fixing nut 100 to 110 Refitting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the starter motor on the crankcase and lock the two screws to the prescribed torque Locking torques N m Starter motor screws 10 8 to 12 8 Engine Ves...

Page 141: ...the intake manifold The intake manifold is positioned on the head loosen the clamps and remove the sleeve con necting to the throttle body Undo the three manifold fixing screws and re move it Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 141 ...

Page 142: ...cker arms cover Remove the protective cover undoing the three screws Remove the engine temperature sensor Undo the screw indicated remove the upper part of the cover Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 142 ...

Page 143: ... Unscrew the four screws and remove the tappet cover Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 143 ...

Page 144: ...s Use the holes on the engine crankcase to secure the tool Position the specific tool in the window between the flywheel pick up references as illustrated in the figure Specific tooling 020941Y Crankshaft timing adjustment tool First loosen the tensioner and unscrew the fixing screws Remove the tensioner complete with gasket Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 144 ...

Page 145: ...ter removing the head the camshaft control com ponents can be removed Remove the inspection cover as described in sec Lubrication Main bushing oil seals removal Remove the oil pump command as described in section Lubrication Oil pump Disassembly Undo the chain tensioner pad fixing screw re move the bushing and the slider Remove the chain tensioner pad Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG...

Page 146: ... Remove the control gear Remove the seal OR Remove the flat washer CAUTION REMEMBER TO CORRECTLY POSITION THE SEAL OR IN THE REFITTING PHASE Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 146 ...

Page 147: ...emove the control gear See also Removal Removing the cylinder piston assy Removing the cam shaft Undo the camshaft lock screw Remove the lock Remove the two pins and the rockers Remove the camshaft Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 147 ...

Page 148: ...Removing the cylinder head Gradually loosen the four screws in crossed se quence and recover the washers Undo the two external screws Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 148 ...

Page 149: ... Remove the cylinder head Remove the chain guide slider and the gasket Remove the gasket N B ON ASSEMBLY PAY CLOSE ATTENTION TO THE TWO DOWELS Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 149 ...

Page 150: ...ng CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS CAUTION DURING ASSEMBLY POSITION THE VALVE SPRINGS WITH THE GREEN COLOURED COIL FACING UPWARD Specific tooling 020382Y Valve fitting removal tool Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 150 ...

Page 151: ...N TO PREVENT DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER N B IN ORDER NOT TO DAMAGE THE BASE GASKET WITH THE PISTON LOCK FORK 020426Y DURING THE MOUNT ING PHASE IT IS RECOMMENDED TO INSERT THE ALIGNMENT DOWELS OF THE CYLINDER CRANKCASE UNDER THE CYLINDER DURING THE ASSEMBLY Remove the base gasket Remove the retainer rings and remove the piston N B BE CAREFUL NOT TO DAMAGE THE SEALIN...

Page 152: ... AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the piston N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the piston rings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Piston rings Engine Vespa LX S 125 3V ie 150 3V ie 2012 EN...

Page 153: ...ic tool Specific tooling 020942Y Piston protrusion check tool Using an abutment plane reset the dial gauge with a preload of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Install the tool on the cylinder without changing the dial gauge position Lock the tool using the original head fixing nuts Rotate the crankshaft up to the TDC the inver sion point of th...

Page 154: ...and D and must be fitted so that the reference arrow faces the exhaust duct The letter is found at the centre of the piston Fit the sealing rings with the word TOP or the identification letter facing upwards In any case the step must be facing opposite the piston crown Sealing rings are manufactured with a cylinder contact conical cross section and piston gaps must be offset by 120 in order to obt...

Page 155: ...BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER LINER Specific tooling 020426Y Piston fitting fork 020427Y Piston assembly band Recommended products eni i Ride PG 10W 40 Synthetic based lubri cant for four stroke engines JASO MA MA2 API SL ACEA A3 Inspecting the cylinder head N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Vespa LX S 125...

Page 156: ...ove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole unit Inspecting the valve sealings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Inspecting the valves N B TO MEASURE WEAR LIMITS AND COUPLIN...

Page 157: ...DE THAT MAY AFFECT THE MEAS UREMENTS Characteristic Valve clearance cold engine intake 0 08 mm exhaust 0 08 mm Inspecting the springs and half cones Check that the upper and lower supporting spring washers the cotters and the oil seal show exhibit no signs of abnormal wear Replace a component when worn N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Vesp...

Page 158: ...gs alternately Fit the valves the springs and the spring retaining caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats N B DO NOT CHANGE THE POSITIONS THE VALVES ARE FIT TED IN FIT THE VALVE SPONGES WITH THE REFERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Specific tooling 020382Y Valve fitting removal tool 020431Y Valve oil seal extracto...

Page 159: ...Head Refitting the head and timing system components Position the crankshaft to the TDC in compres sion Insert the head gasket and check the correct operation of the alignment dowels Insert the chain guide slider Insert the head Lubricate the stud bolt threads with engine oil Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 159 ...

Page 160: ...TION ALWAYS USE A NEW HEAD GASKET UPON REFITTING Locking torques N m Cylinder head nut TIGHTENING 9 to 11 Tighten to the prescribed torque and then proceed with 270 0 5 0 rotation Screws fixing cylinder to crankcase 10 8 to 12 7 Refitting the rocker arms cover Remove the cylinder head cover and tighten the four clamping screws to the prescribed torque Pay attention to the integrity of rubber gaske...

Page 161: ...KSHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT ACCIDENTALLY FALL Remove the gasket and be careful with the align ment dowels Inspecting the crankshaft components N B T...

Page 162: ...th the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase coupling gasket between the crankcase halves or the mating surfaces shown in the diagram could cause a drop in the oil pressure lubricating the main bushings and connecting rod Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear The dimension between these seats...

Page 163: ...t axial clearance of the limiting surface N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Coupling chart N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Refitting the crankcase halves Follow the removal steps but in reverse order be careful...

Page 164: ...ance Using specific tools to support the dial gauge verify that the fitting clearance is within the limits Higher clearances are signs of wear of the crankshaft crankcase supporting surfaces Characteristic Crankshaft crankcase axial clearance 0 2 to 0 5 mm Studs Using two nuts fitted as nut and lock nut type remove and then drive from the seat Proceed with a thorough cleaning of the threaded seat ...

Page 165: ... the main bearings are lubricated and the big end with high pressure the piston pin and connecting rod small end via spray H Subsequently the oil arrives at the timing system where it lubricates the camshaft A and from this valves and rockers The oil passes through the timing chain duct and returns to the sump B by gravity In the system there is a minimal oil pressure sensor I and a spray that ser...

Page 166: ...ate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the flywheel cover If the oil pressure is not within 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 LEVEL AND WITH AN OIL FILTER IN P...

Page 167: ...screw the three screws and remove them complete with the copper gaskets Using pliers remove the door by acting on the appendices Remove the spacer and the O ring Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 167 ...

Page 168: ...n reverse order taking care to tighten to torque WARNING IN ORDER TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE WE RECOM MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH Locking torques N m Crankcase timing cover screws 11 to 13 Oil pump Engine Vespa LX S 125 3V ie 150 3V ie 2012 ENG 168 ...

Page 169: ... the oil shield Preventing rotation unscrew the water pump command screw and collect the washer Remove the oil pump command sprocket com plete with chain Unscrew the two screws and remove the oil pump Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 169 ...

Page 170: ... the rotors in the position shown in the figure Check the distance between the outer rotor and pump body see figure Check the axial clearance of the rotors using a trued bar as shown in the figure Characteristic Axial rotor clearance Limit values admitted 0 09 mm Distance between the outer rotor and the pump body Admissible limit clearance 0 20 mm Distance between the rotors Admissible limit clear...

Page 171: ...E CUP WASHER SO THAT ITS OUTER RIM TOUCH ES THE PULLEY MAKE SURE THAT THE PUMP TURNS FREELY Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Screws fixing oil pump to the crankcase 5 to 6 Preventing rotation tighten the water pump com mand screw complete with washer Vespa LX S 125 3V ie 150 3V ie 2012 Engine ENG 171 ...

Page 172: ...the figure with the two rear brake transmission retainer brackets Remove the washers the spring and the by pass piston 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 Standard length 52 4 ...

Page 173: ...ission mounting brack ets and the screws in the reverse order from which they were removed Tighten the screws to the prescribed torque Refit the driving pulley assembly the drive belt the sprocket wheel and the transmission cover as described in the Transmission chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the connecting rod as...

Page 174: ...INDEX OF TOPICS INJECTION INJEC ...

Page 175: ... by means of a tone wheel keyed on to the crankshaft 24 2 teeth and pick up sensor Combustion and ignition are managed on the basis of engine revs and throttle valve opening Further corrections are made according to the following parameters Engine temperature Intake air temperature Lambda probe The system implements cold engine idle fuel air mixture correction with a stepper motor on a by pass cir...

Page 176: ...ed cap MIU control unit Spark plug The MIU control unit manages ignition with the best advance ensuring four stroke timing ignition only in the compression phase at the same time The MIU injection ignition system controls engine functions by means of a pre set program Should any input signals fail an acceptable working order of the engine is ensured to allow the user to reach a service station Of ...

Page 177: ...20922Y Diagnosis Tool The MIU control unit has a decoder for the anti theft immobilizer system The MIU control unit is connected to a diagnostic LED on the instrument panel that also carries out the deterrent flashing functions Precautions Troubleshooting tips 1 A MIU failure is more likely to be due to the connections than to the components Before troubleshooting the MIU system carry out the foll...

Page 178: ...ng the MIUIf the fault is fixed by replacing the MIU install the original control unit again and check if the fault occurs again 4 Use a multimeter with an internal resistance of more than 10K Ohm V when troubleshooting Instru ments that are not suitable might damage the MIU central control unit Use instruments with definitions over 0 1V and 0 5 W the precision must be greater than 2 1 Before fixi...

Page 179: ...10 Do not invert the poles when fitting the battery 11 To avoid causing any damage disconnect and reconnect the MIU system connectors only if re quired Before reconnecting check that the connectors are dry 12 When carrying out electric inspections do not force the tester probes into the connectors Do not take measurements not specifically foreseen by the manual 13 At the end of every check perform...

Page 180: ...and Brown Red 20 Speed sensor negative Brown 21 Not connected 22 Injection load relay Black Purple 23 Ground No 2 Black 24 Not connected 25 Injection warning light Brown White 26 Not connected 27 Not connected 28 Not connected 29 Engine speed sensor positive Red 30 Not connected 31 Lambda probe heater Light blue Red 32 Not connected 33 Low beam lights automatic ignition enabling White Black 34 Fue...

Page 181: ...THE FOLLOWING INDICACTIONS REFER TO THE S VERSION Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 181 ...

Page 182: ...r remote control switch 18 Fuse No 1 21 Battery 23 Injection load relay 26 Lambda probe 27 Engine speed sensor 28 H V coil 29 Diagnostics socket 30 Injector 31 Engine temperature sensor 32 Fuel pump 33 Side stand switch 34 Electronic control unit Injection Vespa LX S 125 3V ie 150 3V ie 2012 INJEC 182 ...

Page 183: ...ting difficulties ENGINE STARTER PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Start up speed Starter motor and solenoid Battery Ground connections End of compression pressure End of compression pressure Power to the spark plug Spark plug Shielded cap HV coil Speed timing s...

Page 184: ... coil Injector Revolution timing sensor Air temperature Engine temperature Ignition efficiency Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake system sealing infiltrations Intake manifold head Throttle body manifold Air cleaner joint Filter box Fuel system low pressure Fuel pump Pressure regulator F...

Page 185: ...TPS reset successful Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER ENGINE IRREGULAR PERFORM ANCE ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution t...

Page 186: ...lter box TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Fuel supply system The fuel system circuit includes the electric pump the filter the pressure regulator the electro injector and the fuel delivery pipes The electrical pump is located ...

Page 187: ...Removing the injector Remove the helmet compartment Remove the connector from the injector Remove the quick release of the petrol delivery pipes Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 187 ...

Page 188: ...ket CAUTION DO NOT DISASSEMBLE THE INJECTOR COMPONENTS Refitting the injector For refitting perform the removal operations in re verse order and lubricate the sealing OR gasket with grease for internal application before fitting the injector on the manifold Injection Vespa LX S 125 3V ie 150 3V ie 2012 INJEC 188 ...

Page 189: ...ting from the injector Remove the injector connector Remove the three screws with anti tampering device fixing the manifold to the head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector Remove the fastening clamp of the air cleaner joint to the air filter body Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 189 ...

Page 190: ...int manifold and injector Refitting the butterfly valve For refitting perform the steps in the reverse di rection to disassembly taking care to orientate the air cleaner joint by inserting it in the reference tooth on the throttle body as shown in the picture To adjust the throttle control cables act on the specific adjuster screws Injection Vespa LX S 125 3V ie 150 3V ie 2012 INJEC 190 ...

Page 191: ...Pump supply circuit 1 Battery 12V 6 Ah 2 Fuse No 6 of 10A 3 Fuse No 1 20A 4 Ignition switch contacts 5 7 5A fuse No 2 Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 191 ...

Page 192: ...it 2 A to be checked with specific tool for fuel pressure Check efficiency of the fuse No 6 of 10A injection loads next to the battery Check efficiency of fuse No 2 of 7 5A live control unit power supply after removing the central cover of the shield Check efficiency of the injection load relay that can be reached by removing the central cover of the shield check the resistance of the energising c...

Page 193: ...d White cable between the fuse box No 6 10 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Circuit leak test Install the specific tool for checking the fuel pressure with the pipe fitted with the gauge Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 193 ...

Page 194: ...te tool Make a graded burette available with a flow rate of approximately 1 L Rotate the pump using the active diagnosis of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at approx 2 5 bar Check that within 15 seconds the pump has a flow rate of approx 110 cm Specific tooling 020480Y Petrol pressure check kit Fuel filter check A...

Page 195: ...fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture Remove the filter from the pump mounting Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 195 ...

Page 196: ...Inspecting the injector circuit 1 Battery 12V 6 Ah 2 Fuse No 6 of 10A 3 Fuse No 1 20A 4 Ignition switch contacts 5 7 5A fuse No 2 Injection Vespa LX S 125 3V ie 150 3V ie 2012 INJEC 196 ...

Page 197: ... 2 of 7 5A live control unit power supply after removing the central cover of the shield Check efficiency of the injection load relay that can be reached by removing the central cover of the shield check the resistance of the energising coil between pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the relay Vespa LX S...

Page 198: ...base and ground Otherwise check the continuity of the Red White cable between the fuse box No 6 10 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Injection Vespa LX S 125 3V ie 150 3V ie 2012 INJEC 198 ...

Page 199: ...a fascetta di collegamento cor po farfallato al collettore Scollegare il connettore elettrico Liberare il tubo mandata carburante all iniettore dalla staffetta sul corpo farfallato e dalla fascetta che lo fissa al cablaggio elettrico Install the appropriate tool for checking fuel pres sure and position the manifold over a container graduated by at least 100 cm Connect the injec tor with the cable ...

Page 200: ...or seal test Dry the injector outlet with a blast of compressed air Activate the fuel pump Wait for one minute making sure there are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute Injection Vespa LX S 125 3V ie 150 3V ie 2012 INJEC 200 ...

Page 201: ...HT coil 1 Battery 12V 6 Ah 2 Fuse No 6 of 10A 3 Fuse No 1 20A 4 Ignition switch contacts 5 7 5A fuse No 2 Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 201 ...

Page 202: ...nition advance is optimised to stabilise the speed at 1450 50 rpm Magnetisation time The coil magnetisation time is controlled by the control unit The ignition power is increased during the engine start up phase The injection system recognises the 4 stroke cycle so ignition is only commanded in the compression phase Specific tooling 020331Y Digital multimeter Check efficiency of the fuse No 6 of 1...

Page 203: ...5 make sure that there is continuity between pins 30 and 87 of the relay Check the presence of fixed voltage between the Red White cable of the relay base and ground Otherwise check the continuity of the Red White cable between the fuse box No 6 10 A and the relay base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED RELAYS CONTROL UNIT FUSES ETC Vespa LX S 125 3V ie 150 3...

Page 204: ... with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor can also assume various fitting positions For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another To obtain the optimum fuel mixture especially at small openings of the throttle valve it is essential to match the throt...

Page 205: ...ure Reset should be performed in the following cases on first fitting if the injection control unit is replaced N B THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE CALIBRATION Vespa LX S 125 3V ie 150 3V ie 2012 Injection INJEC 205 ...

Page 206: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 207: ...l Support the vehicle adequately Loosen the five screws fixing the wheel to the hub Front wheel hub overhaul Support the vehicle adequately Remove the front wheel Remove the front brake calliper Remove the cotter pin and remove the cap Unscrew the nut fixing the front wheel hub Vespa LX S 125 3V ie 150 3V ie 2012 Suspensions SUSP 207 ...

Page 208: ...picture Extract the ball bearing using the specific tool Specific tooling 001467Y014 Calliper to extract ø 15 mm bear ings 001467Y017 Bell for bearings OD 39 mm Remove the oil seal on the roller bearing side using a screwdriver Suspensions Vespa LX S 125 3V ie 150 3V ie 2012 SUSP 208 ...

Page 209: ... 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 Punch Recommended products AGIP GREASE MU3 Yellow brown lithium base medium fibre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 To refit follow...

Page 210: ...ixing 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 WARNING DO NOT LEAVE THE REMOVED INSTRUMENT DANGLING OR UPSIDE DOWN AS THIS COULD DAMAGE IT IRREP ARABLY FAILURE TO OBSERVE THIS INSTRUCTION CAUSES THE LOSS OF CALIBRATION OF THE INSTRU MENT ...

Page 211: ...vicing the front suspension steering assembly described below deals mainly with replacing parts pin NADELLA roller bushings sealing rings unit and dust gaiter which connect the steering tube to the front wheel holder swinging hub N B BEFORE PROCEEDING WITH THE DESCRIBED SERVICE CHECK THAT THE STEERING TUBE AND THE WHEEL HOLDER HUB ARE IN EXCELLENT CONDITIONS ONLY THEN IS THE SERVICE JUSTIFIABLE MO...

Page 212: ...e figure N B DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED UPON REFITTING IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN NEW SEALING RINGS AND DUST GAITER Specific tooling 020021Y Front suspension service tool Connect the swinging hub to the steering tube with the guiding pin Use the tool fitted with part 3 on the ste...

Page 213: ... the second wedging washer roller bushing sealing ring unit WARNING BEFORE PROCEEDING WITH THE DESCRIBED PRE FIT TING DIP THE SEALING RINGS IN MINERAL OIL AND THE NADELLA ROLLER BUSHINGS PREVIOUSLY WASHED IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMI NATE THE ANTIRUST PROTECTION HALF FILLED WITH GREASE Specific tooling 020021Y Front suspension service tool Recommended products AGIP GREASE MU3 Yello...

Page 214: ... placed in that space By wedging the washers as described above the front suspension unit refitting stage is finished Recommended products AGIP GREASE MU3 Yellow brown lithium base medium fibre multipurpose grease ISO L X BCHA 3 DIN 51 825 K3K 20 Refitting CAUTION USE NEW ROLLER CASINGS PIN SEALING RINGS AND DUST GUARDS FOR REFITTING Suspensions Vespa LX S 125 3V ie 150 3V ie 2012 SUSP 214 ...

Page 215: ...per ring nut B to the specified torque Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Locking torques N m Steering lower ring nut 8 10 Steering upper ring nut 35 to 40 Front shock absorber Vespa LX S 125 3V ie 150 3V ie 2012 Suspensions SUSP 215 ...

Page 216: ...mps and re move the brake calliper shock absorber mounting Loosen the screws fixing the front brake pipe re tainer clamp and the odometer cable in order to reach the upper clamps Unscrew the upper fixing nuts Remove the front shock absorber Suspensions Vespa LX S 125 3V ie 150 3V ie 2012 SUSP 216 ...

Page 217: ... the front shock absorber lower clamps Remove the bracket locking Seeger ring Unscrew the bracket Before refitting the bracket in the wheel axle place the O ring as shown in the photograph so that it is correctly placed after fitting the bracket Refit the washer and the Seeger ring Refit the lower screws fixing the shock absorber to the bracket and tighten at the prescribed torque Locking torques ...

Page 218: ... as shown in the photo graph Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph Suitably hold the brake calliper shock absorber attachment bracket Fit a new oil seal and move it until it stops using the specific tool Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 m...

Page 219: ...rse order of the removal operation CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK LUBRICATE THEM WITH THE RECOMMENDED PRODUCT Specific tooling 020036Y Punch 020037Y Punch Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 NATO G 460 symbol Steering bearing Removal Use the specific tool both to...

Page 220: ...igure using the specific tool Proceed giving a few taps with the mallet Specific tooling 020004Y Punch for removing steering bearings from headstock Refit the fifth wheel fitting and the dust gaiter on the steering bearing until they stop using the spe cific tool Specific tooling 006029Y Punch for fitting steering bearing seat on steering tube Rear Removing the rear wheel Remove the silencer Remov...

Page 221: ...he washer Refitting the rear wheel To refit follow the removal steps but in reverse order be careful to tighten to the prescribed tor que Locking torques N m Locking torque 137 to 152 Nm Swing arm Vespa LX S 125 3V ie 150 3V ie 2012 Suspensions SUSP 221 ...

Page 222: ...d as follows Unscrew the pin and collect the washer Remove the cap from the lower part Collect the lower fixing nut and collect the wash er Working on both sides remove the cover caps Working on the right side unscrew the side fixing nut to the chassis and collect the washer Suspensions Vespa LX S 125 3V ie 150 3V ie 2012 SUSP 222 ...

Page 223: ...xing nut Working on the left side release the pin from the spring shown Remove the fixing pin to the engine and collect the spacer Now the swinging arm is free Remove the swinging arm from the vehicle first release it from the engine side and then from the chassis side Vespa LX S 125 3V ie 150 3V ie 2012 Suspensions SUSP 223 ...

Page 224: ... fit follow the removal steps but in reverse or der be careful to tighten to the prescribed torques Locking torques N m Silent block swinging arm retaining bolts 40 to 45 Swinging arm chassis pin 44 to 52 Engine swinging arm bolt 40 to 45 Shock absorbers Suspensions Vespa LX S 125 3V ie 150 3V ie 2012 SUSP 224 ...

Page 225: ...cribed torques Locking torques N m Shock absorber chassis nut torque 20 25 Nm Lower shock absorber clamp 40 to 45 Centre stand REMOVAL Use a jack to support the vehicle properly Remove the two return springs from the centre stand Undo the nut shown in the figure Remove the pin from the right side Remove the centre stand FITTING On refitting tighten the nut to the specified torque Locking torques N...

Page 226: ...Suspensions Vespa LX S 125 3V ie 150 3V ie 2012 SUSP 226 ...

Page 227: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 228: ...REPLACEMENT IS NEEDED BE FORE REMOVING THE CALLIPER CLAMPS TO THE MOUNTING BRACKET LOOSEN THE OIL JOINT FITTING 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 ...

Page 229: ...ng washer to the prescribed torque If it is disconnected fasten the brake pipe joint to the calliper and tighten to the prescribed torque Purge the circuit and refit the front wheel Locking torques N m Brake calliper mounting clamping 20 to 25 Nm Brake pipe connection 20 to 25 N m Front brake disc Vespa LX S 125 3V ie 150 3V ie 2012 Braking system BRAK SYS 229 ...

Page 230: ... 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 Vespa LX S 125 3V ie 150 3V ie 2012 BRAK SYS 230 ...

Page 231: ...rn and check the disk de viation Specific tooling 020335Y Magnetic mounting 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 pin and the spring Remove the brake pads Check that there are no faults or warping If there are replace them Check that the thickne...

Page 232: ...s towards the bleed screw as in the photo Insert the lock on the bolt and then the protection cover Fix the 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 to 25 Nm Fill Braking system Vespa LX S 125 3V ie 150 3V ie 2012 BRAK SYS 232 ...

Page 233: ...ATIONS 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 OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM Specific tooling 020329...

Page 234: ... replace fluid as indicated in the scheduled maintenance table Front brake pump Removal Remove the front and rear handlebar covers Remove the two screws fixing the brake pump to the handlebar indicated in the photograph Remove the oil pipe joint from the pump Remove the connector from the stop lights switch Refitting To refit carry out the removal operations but in reverse order observing the spec...

Page 235: ...hoe springs using the specific spanner 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mallet 4 Attach the springs using the specific pliers Specific tooling 020325Y Pliers for brake shoe springs Vespa LX S 125 3V ie 150 3V ie 2012 Braking system BRAK SYS 235 ...

Page 236: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 237: ...ar cover Undo the three screws indicated in figure fixing it to the handlebar the odometer transmission and the electrical connectors WARNING DO NOT LEAVE THE REMOVED INSTRUMENT DANGLING OR UPSIDE DOWN AS THIS COULD DAMAGE IT IRREP ARABLY FAILURE TO OBSERVE THIS INSTRUCTION CAUSES THE LOSS OF CALIBRATION OF THE INSTRU MENT PANEL WHICH ALTHOUGH OPERATIONAL INDI CATES INCORRECT VALUES Instrument pan...

Page 238: ...ARNING DO NOT LEAVE THE REMOVED INSTRUMENT DANGLING OR UPSIDE DOWN AS THIS COULD DAMAGE IT IRREP ARABLY FAILURE TO OBSERVE THIS INSTRUCTION CAUSES THE LOSS OF CALIBRATION OF THE INSTRU MENT PANEL WHICH ALTHOUGH OPERATIONAL INDI CATES INCORRECT VALUES Front handlebar cover THE FOLLOWING INDICACTIONS REFER TO THE S VERSION Proceed as follows Remove the rear view mirrors Undo the two screws A Chassis...

Page 239: ... indicator bulb THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION Proceed as follows Remove the rear view mirrors Undo the two screws indicated Undo the screw under the headlamp Laterally release the handlebar cover end Disconnect the electrical terminals and remove the front handlebar cover Vespa LX S 125 3V ie 150 3V ie 2012 Chassis CHAS 239 ...

Page 240: ...ed fixing the front handlebar cover THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION Remove the front handlebar cover Undo the four screws indicated fixing the front handlebar cover Knee guard THE FOLLOWING INDICACTIONS REFER TO THE S VERSION Undo the five screws indicated Chassis Vespa LX S 125 3V ie 150 3V ie 2012 CHAS 240 ...

Page 241: ...THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION Unscrew the two screws shown in the figure placed under the front central cover Remove the 3 screws shown in the figure placed inside the glove box they can be reached opening the glove box door Remove the shield back plate by pulling it up wards Vespa LX S 125 3V ie 150 3V ie 2012 Chassis CHAS 241 ...

Page 242: ...indicated and disconnect the connector Footrest Remove the leg shield back plate Remove the side fairings Remove the central tunnel inspection door From both sides unscrew The fixing screw at the back The fixing screw on the central part Chassis Vespa LX S 125 3V ie 150 3V ie 2012 CHAS 242 ...

Page 243: ... The fixing screw at the front Remove the footrest Side fairings Undo the upper screw and the smallest lower screw Detach the seats on the fairing Vespa LX S 125 3V ie 150 3V ie 2012 Chassis CHAS 243 ...

Page 244: ... the two screws in dicated Remove the license plate light Air filter Remove the helmet compartment Disconnect the air intake pipe from the filter box Remove the side fairings Undo the two indicated clamps to the crankcase Chassis Vespa LX S 125 3V ie 150 3V ie 2012 CHAS 244 ...

Page 245: ...ake 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 LX S 125 3V ie 150 3V ie 2012 Chassis CHAS 245 ...

Page 246: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 247: ...gine swinging arm pin Engine arm pin Chassis arm Handlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system Battery Main switch Headlamps high beam lights low beam lights tail lights and their warning lights Adjusting the headlights according to the regulations currently in force Rear light brake light and license plate light Front and rear stop light sw...

Page 248: ...EEK IMMEDIATE MEDICAL ATTENTION IF IT ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF TH...

Page 249: ... INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Proper general functioning and no abnormal noise check Others Check documentation Check the chassis and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirro...

Page 250: ...ulbs C Checks 78 E Engine oil 42 F Fuel 186 194 Fuses 91 H Headlight 47 240 Horn 86 Hub oil 40 I Identification 8 Instrument panel 237 M Maintenance 7 38 O Oil filter 44 R Recommended products S Shock absorbers 224 Spark plug 38 Suspension 51 T Transmission 10 50 115 127 Turn indicators 74 ...

Page 251: ...Tyres 11 V Vehicle 8 110 ...

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VESPA S 2012, Service Station Manual

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Summary of Contents for S 2012

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