SERVICE STATION MANUAL 677662 EN
Vespa LX - S 125 3V ie 150 3V ie (2012)
SERVICE STATION MANUAL
Vespa LX - S 125 3V ie 150 3V ie (2012)
The The descr escrip ipttions ions and and images ages in this public blicat atio ion n are are given iven for illu illust stra rattive ive purp urposes oses only only and and are are not not bind bindin ing g. While the basic specifications specifications as described and illus illustrat trated ed in this manual manual remain unchanged, unchanged, Piaggio P iaggio Việt Nam reserves reserves the right, at any time time and without being required, to update this publication public ation beforehand, beforehand, to make make any changes to components, components, parts or accessories accessories,, which it considers considers necessary neces sary to improve improve the product or which are required for manufacturing manufacturing or construct construction ion reasons. reas ons. 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 P iaggio sales network. network. "©Copyright 2013 - PIAGGIO VIỆ T NAM. NAM. All All righ ights res reser erv ved. ed. Repr Reprodu oductio ction n of this publica licattion ion in whole ole or in part is prohibited." PIAGGIO VIỆ T NAMNAM- Aft After Sales Sales LOT M - BINH XUYE XUYEN N INDUSTR INDUSTRIAL IAL ZONE - VINCH PHUC - VIET NAM CUSTOMER SERVICE CENTRE Please contact with us following: Hot line: 1800 5555 85 Email:
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SERVICE STATION MANUAL Vespa LX - S 125 3V ie 150 3V ie (2012) This This s ser erv vice ice stat statio ion n manu anual has bee been n dr drawn awn up up by by Piagg Piaggio & C. Spa to be be use used d by by the wor work kshop shops s of P iaggio dealers. It is assum assumed ed that the user of this m manual anual for maintaining maintaining and repairing Piaggio Piaggio vehicles has a basic basic knowledge of m mechanical echanical principles and vehicle repair technique technique procedures. Any significant significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.
N.B. P rovides key key information information to make make the procedure easier easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment S ections marked wit with h this sym symbol bol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
ENG
INJECTION
INJEC
SUSPENSIONS
SUSP
BRAKING SYSTEM CHASSIS PRE-DELIVERY
BRAK SYS CHAS PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
This This sect sectio ion n descr escrib ibes es the gener eneral al spec specif ific icat atio ion ns of of the vehic ehicle le..
Rules This This sect sectio ion n descr escrib ibes es gener eneral al saf safety ety rules les for for any any main aintenan enance ce oper operat atio ion ns p per erfform ormed on the vehic ehicle le..
Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such 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, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
Vehicle identification
THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION.
VEHICLE IDENTIFICATION VESPA LX Specification C hassis prefix (125) E ngine prefix (125) C hassis prefix (150) E ngine prefix (150)
Desc./Quantity ZAP M68300 - 10000001 M669M 1001 ZAP M68400 - 10000001 M66AM - 1001
THE FOLLOWING INDICACTIONS REFER TO THE S VERSION.
VEHICLE IDENTIFICATION VESPA S Specification C hassis prefix (125) E ngine prefix (125) C hassis prefix (150) E ngine prefix (150)
Desc./Quantity ZAP M68301 - 10000001 M669M 1001 ZAP M68401 - 10000001 M66AM - 1001
Chassis number
The The chas chassi sis s number «A» is stamped near the battery compartment. To read read it procee oceed d as follo ollow ws: - lift the saddle; - lift the helmet compartment by removing it.
Engine number
The The eng engine ine number ber «B» is stamped near the rear left shock absorber lower support.
Dimensions and mass
THE FOLLOWING INDICACTIONS REFER TO THE LX VERSION.
CHAR - 8
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
THE FOLLOWING INDICACTIONS REFER TO THE S VERSION.
CHAR - 9
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
WEIGHTS AND DIMENSIONS Specification Length Width Maximum height Wheelbase Kerb weight Maximum weight allowed
Desc./Quantity 1770 mm 705 mm 1150 mm 1280 mm 114 kg ±5 kg 264 kg
Engine 125 CM³ ENGINE SPECIFICATIONS SPECIFICATIONS Specification Type Type E ngine capacity Bore x stroke Max. power MAX. torque C ompression ratio Idle speed Valve clearance (cold engine) Timing ing syst system em Lubrication C ooling F ue uel system F uel E xh xhaust silencer E missions compliance
Desc./Quantity Singl Single-c e-cyl ylin inde der, r, 4-st 4-stro roke ke 124.5 cm³ 52.0 x 58.6 mm 7.2 kW at 7750 rpm 9.5 Nm at 6000 rpm 10:1 1750±50 rpm intake: 0.08 mm exhaust: 0.08 mm 3 valve alves s (2 (2 int intake, ake, 1 drai draina nag ge). e). sin singl gle e ov overhe erhead ad cam camshaf shaftt chain-driven. E ngine lubrication with lobe pump (inside crankcase), chaindriven, with double filter: mesh and paper. F orced-air circulation cooling. E le lectronic injection with Ø 26 26 mm throttle body, single injector. Unleaded petrol (95 RON) Absorption-type ex exhaust muffler with catalytic co converter. E UR O 3
150 CM³ ENGINE SPECIFICATIONS SPECIFICATIONS Specification Type Type E ngine capacity Bore x stroke Max. power MAX. torque C ompression ratio Idle speed Valve clearance (cold engine) Timing ing syst system em Lubrication C ooling F ue uel system F uel E xh xhaust silencer E missions compliance
Desc./Quantity Singl Single-c e-cyl ylin inde der, r, 4-st 4-stro roke ke 154.8 cm³ 58.0 x 58.6 mm 8.7 kW at 7500 rpm 12 Nm at 5000 rpm 10.5: 1 1750±50 rpm intake: 0.08 mm exhaust: 0.08 mm 3 valve alves s (2 (2 int intake, ake, 1 drai draina nag ge). e). sin singl gle e ov overhe erhead ad cam camshaf shaftt chain-driven. E ngine lubrication with lobe pump (inside crankcase), chaindriven, with double filter: mesh and paper. F orced-air circulation cooling. E le lectronic injection with Ø 26 26 mm throttle body, single injector. Unleaded petrol (95 RON) Absorption-type ex exhaust muffler with catalytic co converter. E UR O 3
Transmission TRANSMISSION Specification Tran Transmiss smissio ion n
F inal reduction gear
CHAR - 10
Desc./Quantity CVT expa expand ndab able le pull pulley ey varia ariattor with ith torqu orque e serve server, r, V-b V-bel eltt, selfselfventilating dry automatic centrifugal clutch and transmission housing with forced-circulation air cooling. Gear reduction unit in oil bath.
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
Capacities CAPACITIES Specification E ngine oil Hub oil F uel tank capacity
Desc./Quantity 1220 cm³ (of which 120 cm³ in the filtering cartridge) 200 cm³ ~7 litres ±0.5 litres
Electrical system ELECTRICAL Specification E lectric Ignition
SYSTEM
Desc./Quantity E lectric starter E lectronic inductive discharge ignition, with variable advance and separate HV coil. Three-dimensional map managed by control unit NGK C R 8E B 0.7 to 0.8 mm
Ignition advance Spark plug E lectrode gap
Frame and suspensions FRAME AND SUSPENSION Specification C hassis F ro ront suspension R ea ear suspension
Desc./Quantity Stamped plate body with welded structural reinforcements. S in ingle arm with helical spring and single double-acting hydraulic shock absorber. Double-acting shock absorber, adjustable to four positions at preloading.
Brakes BRAKES Specification F ront brake Rear brake
Desc./Quantity Ø 200-mm disc brake with hydraulic control activated by handlebar right-side lever. Ø 110-mm drum brake with mechanical control activated by handlebar left-side lever.
Wheels and tyres WHEELS AND TYRES Specification Wheel rim type F ront wheel rim R ear wheel rim F ront tyre R ear tyre F ront tyre pressure R ear tyre pressure (with passenger)
Desc./Quantity Light alloy wheel rims. 11'' x 2.50 10'' x 3.00 Tubeless, 110/70 - 11'' 45L Tubeless, 120/70 - 10'' 54L 1.6 bar 2.0 bar (2.3 bar)
CHAR - 11
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
Tightening Torques CHASSIS ASSEMBLY Name S winging arm - chassis pin E ngine-swinging arm bolt S ilent block-swinging arm retaining bolts C entre stand pin
Torque in Nm 44 to 52 40 to 45 40 to 45 40 to 45
STEERING ASSEMBLY Name Steering upper ring nut Steering lower ring nut Handlebar fixing screw
Torque in Nm 35 to 40 12 to 14 50 to 55
FRONT BRAKE Name Brake fluid pump-hose fitting Brake fluid pipe-calliper fitting S crew tightening calliper to support Brake disc screw (°) Oil bleed valve (on the calliper) Handlebar pump Brake pump reservoir screw
Torque in Nm 8 to 12 20 ÷25 20 - 25 5 to 6.5 10 to 12 7 ÷10 15 to 20
(°) Apply LOCTITE 242 threadlock
MUFFLER Name S ilencer heat guard fixing screw Screws fixing silencer to the crankcase Lambda probe tightening on exhaust manifold
Torque in Nm 4 to 5 24 ÷27 40 to 50
FRONT SUSPENSION Name S hock absorber upper nut F ront wheel axle nut S hock absorber upper bracket bolts Wheel screw Shock absorber lower bolts (°)
Torque in Nm 20 to 30 75 to 90 20 to 25 20 to 25 20 to 27
(°) Apply LOCTITE 242 threadlock
REAR SUSPENSION Name Rear wheel axle Shock-absorber/chassis nut Lower shock absorber clamp
Torque in Nm 104 ÷126 20 to 25 40 to 45
FLYWHEEL Name F lywheel cover screw Starter sprocket check fixing screw S tarter motor fixing screws F lywheel fixing nut F reewheel fixing screws
Torque in Nm 11 ÷13 5 to 6 11 to 13 100 to 110 10 to 11
FLYWHEEL COVER Name P ick-up screws
CHAR - 12
Torque in Nm 3- 4
Vespa LX - S 125 3V ie 150 3V ie (2012)
Name Stator fixing screws S tator cable plates clamping screws F ixing clamps of head pump cover by-pass pipe Coil fixing screw
Characteristics
Torque in Nm 5 to 6 (Loctite 242) 3- 4 1.3 to 1.7 11 to 13
CRANKCASE Name Calibrated fixing dowel Oil filter cover E ngine oil level shaft E ngine-crankcase coupling screws R ear brake screw Oil sensor Oil filter Oil drain screw Oil pump bulkhead screw F reewheel fixing screws Oil pump fixing screw Oil pump command crown screw R otor cover R otor clamp
Torque in Nm 5- 7 24 to 30 1.3 to 1.7 11 ÷13 15 to 17 12 to 14 5 to 6 14.7 to 16.7 4 to 6 10 to 11 5 to 6 10 to 14 1 to 1.50 3 to 4
HEAD AND CYLINDER Name Head cover screws C ylinder head nut (P RE -TIGHTE NING) Cyli Cylin nder head ead nu nut (TIGHTEN (TIGHTENIN ING) G) Cylinder stud bolt fitting Thro Throtttle body body clam clamp screw screws s Tensio Tension ner spri sprin ng ret retain aining ing screw screw F astener chain tensioner Therm Thermostat cove coverr screw screws s P ressure reducer counterweight retainer screw Injection manifold fixing screws Valve clearance adjustment screw Spark plug tightening Timing ing syst system em spro sprock cket et fixi fixing ng screw screw Screws fixing cylinder to crankcase Head blow by
Torque in Nm 10.8 to 12.7 6- 8 9 to 11 (Tig (Tighten to the presc rescrribed ibed torq orque and and then procee oceed d with 270.0°±5.0° rotation) See section E NGINE /LUBR IC ATION/STUD BOLT 1.3 1.3 to 1.7 1.7 5 to 6 11 to 13 3- 4 7 to 8.5 11 to 13 6 to 9 10 to 12 4 to 6 10.8 to 12.7 3 to 4
TRANSMISSION AND FINAL REDUCTION Name Trans Transm missio ission n cove coverr screw screws s F inal reduction cover screws Driven pulley fixing nut Oil drain screw F reewheel fixing screws Driving pulley retainer nut
Torque in Nm 11 to 13 24 to 27 53 to 59 14.7 to 16.7 10 to 11 75 to 83
LUBRICATION Name C rankcase timing cover screws S crews fixing oil pump to the crankcase P ump rod screw Min Minimum oil oil pr pressu essure re sen senso sorr loc locki kin ng
Torque in Nm 11 to 13 4 to 6 13 - 15 12 to 14 (LOCTITE (LOCTITE 50 5091 Edge Edge clo closu surre bet between een metal body ody and and plastic block)
Overhaul data
CHAR - 13
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
Assembly clearances
Cylinder - piston assy.
CYLINDER - PISTON (125) Specification P iston diameter C ylinder diameter
Desc./Quantity 51.961 (±0.014) mm 52 (+0.008 -0.020) mm
CYLINDER - PISTON (150) Specification P iston diameter C ylinder diameter
Desc./Quantity 57.947 (±0.014) mm 58 (+0.008 -0.020) mm
COUPLING CATEGORIES (125) Name cylinder-piston cylinder-piston cylinder-piston cylinder-piston
Initials A B C D
Cylinder 51.980 to 51.987 51.987 to 51.994 51.994 to 52.001 52.001 to 52.008
Piston 51.947 to 51.954 51.954 to 51.961 51.961 to 51.968 51.968 ÷51.975
Play on fitting 0.026 ÷0.040 0.026 ÷0.040 0.026 ÷0.040 0.026 ÷0.040
COUPLING CATEGORIES (150) Name cylinder-piston cylinder-piston cylinder-piston cylinder-piston
Initials A B C D
Cylinder 57.980 to 57.987 57.987 to 57.994 57.994 to 58.001 58.001 to 58.008
Piston 57.933 to 57.940 57.940 to 57.947 57.947 to 57.954 58.954 to 58.961
Play on fitting 0.040 to 0.054 0.040 to 0.054 0.040 to 0.054 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.
CHAR - 14
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
- Measure the outer diameter of the gudgeon pin.
Characteristic Pin outside diameter
14 (+0 -0.004) mm
- Measure Measure the diameter diameter of the the housings on the piston.
Characteristic Standard diameter
14 (+0.006 +0.001) mm
- Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston. - Check the clearance upon 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 DESIGNATION 1° compression ring (mm) 2° compression ring (mm) Oil ring segments (mm)
ASSEMBLY CLEARANCE DESIGNATION 1° compression ring (mm) 2° compression ring (mm) Oil ring segments (mm)
OF BANDS
- SEAL RINGS (125)
SIZES 52x0.8 52x1.0 52x2.0 OF BANDS
ASSEMBLY CLEARANCES (A) 0.20 to 0.35 0.20 to 0.45 0.25 to 0.55
- SEAL RINGS (150)
SIZES 58x0.8 58x1.0 58x2.0
ASSEMBLY CLEARANCES (A) 0.20 to 0.35 0.20 to 0.45 0.25 to 0.55
- Check that the head coupling surface is not worn or misshapen.
CHAR - 15
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
- Pistons and cylinders are classified according to diameter. The coupling is carried out in pairs (A-A, B-B, C-C, C-C , D-D). D-D).
Crankcase - crankshaft - connecting rod CRANKSHAFT Titolo C rankshaft
Durata/Valore
Testo Breve (< 4000 car.) Axial clearance between crankshaft and connecting rod
Indirizzo Immagine
Axial clearance between crankshaft and connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Half-shaft, transmission side F lywheel-side half shaft Connecting rod Spacer tool
Diameter of crankshaft bearings.
Measure the bearings on both axes x-y.
CHAR - 16
Code A B C E
Sizes 18.1 (+0; -0.05) mm 18.1 (+0; -0.05) mm 15 (-0.10; -0.15) mm 51.4 (+0; +0.05) mm
Assembly clearance D =0.20 - 0.50 D =0.20 - 0.50 D =0.20 - 0.50 D =0.20 - 0.50
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
CRANKSHAFT Specification Crankshaft bearings: Standard diameter: C at. 1 Crankshaft bearings: Standard diameter: C at. 2
Desc./Quantity 26.998 to 27.004 mm 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
CHAR - 17
Vespa LX - S 125 3V ie 150 3V ie (2012)
Characteristics
- The main bushings have 2 half-bearings, 1 with and 1 without the lubrication channel. - The solid half-bearing is intended to stand the thrusts thrusts caused caused by combustion, combustion, and for this reason it is arranged opposite the cylinder. - To prevent shutters in the oil feeding channels, the matching matching surface surface of the two half-bearings half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the photo.
Characteristic «A»
AXIS CYLINDER
BUSHINGS TYPE B C E
CHAR - 18
IDENTIFICATION BLUE Y E LLOW GR E E N
CRANKSHAFT HALF-BEARING 1.971 to 1.976 1.974 to 1.979 1.977 to 1.982
