WORKSHOP MANUAL - VespaClubUSA

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WORKSHOP MANUAL633416Vespa LX 50

WORKSHOPMANUALVespa LX 50The descriptions and illustrations given in this publication are not binding. While the basic specificationsas described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, atany time and without being required to update this publication beforehand, to make any changes tocomponents, parts or accessories, which it considers necessary to improve the product or which arerequired for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of singlemodels should be checked at the official Piaggio sales network." Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publicationin whole or in part is prohibited."PIAGGIO & C. S.p.A. - After-SalesV.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

WORKSHOP MANUALVespa LX 50This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have abasic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any importantchanges made to the vehicles or to specific fixing operations will be promptly reported by updates to thismanual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools areunavailable. It is therefore advisable to read the sections of this manual relating to specific tools, alongwith the specific tool catalogue.N.B. Provides key information to make the procedure easier to understand and carry out.CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF NTROUBLESHOOTINGTROUBLELECTRICAL SYSTEMELE SYSENGINE FROM VEHICLEENG VEENGINEENGSUSPENSIONSSUSPBRAKING SYSTEMCHASSISPRE-DELIVERYTIMEBRAK SYSCHASPRE DETIME

INDEX OF TOPICSCHARACTERISTICSCHAR

Vespa LX 50CharacteristicsRulesThis section describes general safety rules for any maintenance operations performed on the vehicle.Safety rules- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaustfumes are toxic.- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid ishighly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant waterand seek immediate medical attention.- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparksor 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 workingarea, 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 thatyou do not breathe in the dust produced by the wear of the friction material. Even though the lattercontains no asbestos, inhaling dust is harmful.Maintenance rules- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original ornon-conforming spare parts 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 allthe work surfaces, except tapered couplings, before refitting these parts.- After refitting, make sure that all the components have been installed correctly and work properly.- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts andscrews are not interchangeable with coupling members with English measurement. Using unsuitablecoupling members and tools may damage the scooter.- When carrying out maintenance operations on the vehicle that involve the electrical system, makesure the electric connections have been made properly, particularly the ground and battery connections.CHAR - 7

Vespa LX 50CharacteristicsVehicle identificationVEHICLE IDENTIFICATIONSpecificationChassis prefixEngine prefixDesc./QuantityZAPC38101 1001C381M 1001Dimensions and massWEIGHT AND DIMENSIONSSpecificationDry weightMaximum heightWheelbaseLengthWidthCHAR - 8Desc./Quantity96 4 Kg1140 mm1290 mm1755 mm740 mm

Vespa LX 50CharacteristicsEngineENGINESpecificationEngine typeBore x strokeCubic capacityCompression ratioCarburettorCO adjustmentEngine idle speedAir filterStarting systemLubricationDesc./QuantityTwo-stroke, single cylinder Piaggio Hi-PER240 X 39.3 mm49.40 cc10,3 :1DELL'ORTO PHVA 17.53.5% 0.51800 to 2000 r.p.m.Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and50% unleaded petrol).electric starter/kick starterWith blend and variable oil variable according to the enginerevolutions and the throttle valve opening by means of a pumpcontrolled by the driving shaft with toothed belt.CHAR - 9

Vespa LX 50CharacteristicsSpecificationFuel supplyDesc./QuantityGravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor.forced coolant circulation systemCooling ssionDesc./QuantityWith automatic expandable pulley variator, torque server, Vbelt, automatic clutch, gear reduction unit.CapacitiesCAPACITYSpecificationRear hub oiloil mixer tankFuel tank capacityDesc./QuantityQuantity: approx. 85 ccPlastic, capacity 1.2 l 8.5 l (2 l of which is reserve)Electrical systemELECTRICAL SYSTEMSpecificationType of ignitionIgnition advance (before TDC)Recommended spark plugBatteryMain fuseGeneratorDesc./QuantityCapacitive discharge type electronic ignition, with incorporatedhigh voltage coilFixed 17 1CHAMPION RN2C12V-4Ah7.5 AIn alternate current with three output sectionsFrame and suspensionsCHASSIS AND SUSPENSIONSSpecificationTypeFront suspensionFront suspension strokeTrail (suspension rebounded/compressed)Rear suspensionRear suspension travel:Desc./QuantityUnitised body made of stamped plateSingle arm suspension with swinging arm articulated to thesteering tube. Hydraulic double-acting shock absorber and coaxial spring70 mm71/68 mmSingle hydraulic double-acting shock absorber, helical coaxialspring. Chassis to engine support with swinging arm.83.5 mmBrakesBRAKESSpecificationFront brakeRear brakeCHAR - 10Desc./QuantityDisc brake (Ø 200 mm) with hydraulic control (lever on the farright of the handlebar) and fixed calliper.Ø110 mm drum brake

Vespa LX 50CharacteristicsWheels and tyresWHEELS AND TYRESSpecificationFront tyre sizeRear tyre sizeFront tyre pressureRear tyre pressure:Light alloy rims (Front rim)Light alloy rims (rear rim)Desc./Quantity110/70"-11"120/70-10"1.6 bar2 bar2.50" x 11"3.00 x 10"N.B.CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUSTPRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.Secondary airFollow these steps to clean the sponge filters ofthe secondary air system:1) Remove the snap-on plastic cover (1) on thetransmission cover using a small screwdriver as alever on the retaining tongues in order to insert oneof the three slots found on that cap.2) Wash the polyurethane sponge with water andsoap, dry all components with compressed air andrefit to place. Refit the intake cap respecting theangle reference.3) Undo the two fixing screws (2) on the aluminiumcover of the secondary air housing in order toreach the polyurethane sponge inside that housing; clean as indicated in point 2) and refit allelements after checking the steel tab is not deformed and/or does not guarantee correct tightness at its fitting; replace if necessary.N.B.UPON REFITTING, MAKE SURE TO CORRECTLY FIT THETAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMINIUM COVERS.CAUTIONWHILE CARRYING OUT OPERATION 3), ALWAYS CHECKTHE TWO RUBBER COUPLINGS (3) ON ONE END OF THESECONDARY AIR PIPE FOR CORRECT TIGHTNESS ANDCONTINUITY; IF NECESSARY, REPLACE THEM AND USENEW CLAMPS TO FIX THEM.CHAR - 11

Vespa LX 50CharacteristicsCarburettor50cc VersionDell'OrtoDELLORTO CARBURETTORSpecificationTypeDiffuser diameterRegulation reference numberMaximum nozzle:Maximum air nozzle (on the body):Tapered pin stamped code:Pin position (notches from above):Diffuser:Minimum nozzle:Minimum air nozzle (on the body):Initial minimum mix screw opening:Starter jetStarter air nozzle (on the body):Stroke of starter pin:Gasoline inlet holeDesc./QuantityPHVA 17.5 RDØ 17.5842353Ø 1.5A221209 HA32Free1 1/250Ø 1.511 mmØ 1.5Tightening TorquesFRONT BRAKENameBrake fluid pump-hose fittingBrake fluid pipe-calliper fittingScrew tightening calliper to supportBrake disc screwOil bleed valve (on the calliper)Handlebar pumpTorque in Nm8 1220 2520 255 6.510 127 10FRONT SUSPENSIONNameShock absorber upper nutFront wheel axle nutShock absorber upper bracket boltsWheel rim screwsShock absorber lower bolts ( )Torque in Nm20 3075 9020 2520 2520 27STEERING ASSEMBLYNameUpper steering ring nutSteering lower ring nutHandlebar fixing screwTorque in Nm35 408 1050 55ENGINE ASSEMBLYNameClutch bell nut (**)Clutch lock ring nutNut locking driving pulley on crankshaft (**)Start-up lever screwFlywheel nut (**)CHAR - 12Torque in Nm40 4455 6040 44 Nm12 1340 44

Vespa LX 50CharacteristicsNameFlywheel fan screwsHalf-crank case joint boltsBolts holding exhaust pipe to the crankcaseScrews holding the filter box to the crank caseHead nutsStarter screwsIgnition spark plugHub oil drainage capOil hub level dipstickRear hub cap screwsTransmission cover screwsInlet manifold screwsFlywheel hood fixing screwsCylinder hood fixing screwsStator clamping screwsPick-Up clamping screwMixer clamping screwsScrew fixing brake lever to the journal on the engineTorque in Nm3 412 1322 244 510 1112 1325 303 5Manual12 1312 138 91 23.5 53 44 53 412 13FRAME ASSEMBLYNameSwinging arm - engine pin*Swinging arm pin - frameShock absorber - chassis nut (*)Swinging arm - frame plateshock absorber - engine pin (*)Rear wheel nutSide stand fixing screwSide stand bracket fixing screwTorque in Nm33 4144 5220 to 25 Nm33 4133 to 41 N·m137 15212 2015 20Overhaul dataAssembly clearancesCylinder - piston assy.COUPLING BETWEEN PISTON AND CYLINDERNameStandard couplingStandard couplingStandard couplingStandard couplingcoupling 1st oversizecoupling 1st oversizecoupling 1st oversizecoupling 1st oversizeCoupling 2nd oversizeCoupling 2nd oversizeCoupling 2nd oversizeCoupling 2nd oversizeInitialsMNOPM1N1O1P1M2N2O2P2Cylinder40.005 - 40.01240.012 - 40.01940.019 - 40.02640.026 - 40.03340.205 - 40.21240.212 - 40.21940.219 - 40.22640.226 - 40.23340.405 - 40.41240.412 - 40.41940.419 - 40.42640.426 - 40.433Piston39.943 - 39.9539.95 - 39.95739.957 - 39.96439.964 - 39.97140.143 - 40.1540.15 - 40.15740.157 - 40.16440.164 - 40.17140.343 - 40.3540.35 - 40.35740.357 - 40.36440.364 - 40.371Play on fitting0.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.0690.055 - 0.069CHAR - 13

Vespa LX 50CharacteristicsPiston ringsSEALING RINGNameCompression ringCompression ring 1stoversizeCompression ring antity0.10 to 0.250.10 to 0.2540.4A0.10 to 0.25Crankcase - crankshaft - connecting rodAXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING RODNameConnecting rodDimensions11.750-0.05InitialsAshoulder washer0.5 0.03GHalf-shaft, transmissionside13.75 0.040CFlywheel-side half-shaft13.75 0.040DLining between theshoulders40.64HCage11.800-0.35BCHAR - 14DescriptionQuantityclearance E 0.25 to0.50clearance E 0.25 to0.50 - clearance F 0.20 to 0.75clearance E 0.25 to0.50 - clearance F 0.20 to 0.75clearance E 0.25 to0.50 - clearance F 0.20 to 0.75clearance E 0.25 to0.50 - clearance F 0.20 to 0.75clearance F 0.20 to0.75

Vespa LX 50CharacteristicsSlot packing systemThis type of engines foresees the use of one size of basic gaskets.ProductsRECOMMENDED PRODUCTS TABLEProductAGIP ROTRA 80W-90AGIP CITY HI TEC 4TAGIP FILTER OILAGIP CITY TEC 2TAGIP BRAKE 4MONTBLANC MOLYBDENUMGREASEAGIP GREASE PV2AGIP GREASE SM 2AGIP GP 330DescriptionRear hub oilSpecificationsSAE 80W/90 Oil that exceeds the requirements of API GL3 specificationsOil to lubricate flexible transmissionsOil for 2-stroke engines: SAE 5W-40, API(brake, throttle control and mixer, odomSL, ACEA A3, JASO MAeter)Oil for air filter spongeMineral oil with specific additives for increased adhesivenessMixer oilsynthetic oil for 2-stroke engines: JASOFC, ISO-L-EGDBrake fluidFMVSS DOT 4 Synthetic fluidGrease for driven pulley shaft adjustingGrease with Molybdenum disulphidering and movable driven pulley housingGrease for the steering bearings, pinWhite anhydrous-calcium based greaseseats and swinging armto protect roller bearings; temperaturerange between -20 C and 120 C; NLGI2; ISO-L-XBCIB2.Grease for odometer transmission gear Lithium grease with NLGI 2 molybdenumcasedisulphide; ISO-L-XBCHB2, DINKF2K-20Grease for brake control levers, throttle,White calcium complex soap-basedstandspray grease with NLGI 2; ISO-L-XBCIB2CHAR - 15

INDEX OF TOPICSTOOLINGTOOL

Vespa LX 50ToolingATTREZZATURAStores code001330YDescriptionTool for fitting steering seats001467Y006Pliers to extract 20 mm bearings001467Y009Driver for OD 42-mm bearings001467Y013Pliers to extract ø 15-mm bearings001467Y014Pliers to extract ø 15-mm bearings001467Y017Bell for bearings, OD 39 mm002465YPliers for circlipsTOOL - 17

Vespa LX 50ToolingTOOL - 18Stores code006029YDescriptionPunch for fitting fifth wheel seat on steering tube020004YPunch for removing fifth wheels fromheadstock020055YWrench for steering tube ring nut020150YAir heater support020151YAir heater020162YFlywheel extractor020163YCrankcase splitting plate

Vespa LX 50ToolingStores code020166YDescriptionPin lock fitting tool020261YStarter spring fitting020265YBearing fitting base020325YPliers for brake-shoe springs020329YMity-Vac vacuum-operated pump020330YStroboscopic light to check timingTOOL - 19

Vespa LX 50ToolingTOOL - 20Stores code020331YDescriptionDigital multimeter020332YDigital rpm indicator020333YSingle battery charger020334YMultiple battery charger

Vespa LX 50ToolingStores code020335YDescriptionMagnetic support for dial gauge020350YElectrical system check instrument020359Y42x47-mm Adaptor020376YAdaptor handle020412Y15-mm guideTOOL - 21

Vespa LX 50ToolingTOOL - 22Stores code020456YDescriptionØ 24 mm adaptor020565YFlywheel lock calliper spanner494929YExhaust fumes analyser001467Y029Bell for bearings, O.D. 38 mm020037YPunch020036YPunch

Vespa LX 50ToolingStores code020021YDescriptionFront suspension service tool020038YPunch020074YSupport base for checking crankshaftalignment004499Y001Bearing extractor bell004499Y006Bearing extractor ringTOOL - 23

Vespa LX 50ToolingTOOL - 24Stores code004499Y002DescriptionBearing extractor screw004499Y007Half rings020171YPunch for driven pulley roller bearing020340YFlywheel and transmission oil seals fittingpunch020360Y52x55-mm Adaptor020358Y020362Y37x40-mm Adaptor12 mm guide

Vespa LX 50ToolingStores code020363YDescription20-mm guide020365Y22 mm guide020439Y17-mm guide020441Y26 x 28 mm adaptor020452YTube for removing and refitting the drivenpulley shaftTOOL - 25

Vespa LX 50ToolingTOOL - 26Stores code020451YDescriptionStarting ring gear lock020444YTool for fitting/ removing the driven pulleyclutch

INDEX OF TOPICSMAINTENANCEMAIN

Vespa LX 50MaintenanceMaintenance chartEVERY 2 YEARSActionBrake fluid - changeAFTER 1000 KM50'ActionHub oil - changeOil mixer/throttle linkage - adjustmentOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake fluid level - checkSafety locks - checkElectrical system and battery - checkTyre pressure and wear - checkVehicle and brake test - road testAFTER 5000 KM, 25000 KM, 35000 KM AND 55000 KM40'ActionHub oil level - checkSpark plug/electrode gap - replacementAir filter - cleanOil mixer/throttle linkage - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkElectrical system and battery - checkTyre pressure and wear - checkVehicle and brake test - road testAFTER 10000 KM, 50000 KM95'ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentOil mixer/throttle linkage - adjustmentVariable speed rollers - replacementOdometer gear - greasingDriving belt - checkingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkVehicle and brake test - road test(*) See regulations in the «Adjusting the idle speed» sectionAFTER 15000 KM AND 45000 KM65'MAIN - 28

Vespa LX 50MaintenanceActionHub oil level - checkSpark plug/electrode gap - replacementAir filter - cleaningOil mixer/throttle linkage - adjustmentDriving belt - replacementBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkElectrical system and battery - checkTyre pressure and wear - checkSAS box (sponge) (**) - cleaningVehicle and brake test - road test(**) See regulations in the «Secondary air system» sectionAFTER 20000 KM AND 40000 KM110'ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentCylinder cooling system - check/cleaningOil mixer/throttle linkage - adjustmentDriving belt - checkingVariable speed rollers - replacementMixer belt - replacementOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkVehicle and brake test - road test(*) See section «Adjusting the idle speed»AFTER 30000 KM130'ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentOil mixer/throttle linkage - adjustmentDriving belt - replacementVariable speed rollers - replacementOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearFlexible brake tubes - replacementBrake fluid level - checkTransmission elements - lubricationSafety locks - checkSuspensions - checkElectrical system and battery - checkHeadlight - adjustmentTyre pressure and wear - checkSAS box (sponge) (**) - cleaningVehicle and brake test - road testMAIN - 29

Vespa LX 50Maintenance(*) See regulations in the «Adjusting the idle speed» section(**) See regulations in the «Secondary air system» sectionAFTER 60000 KM150'ActionHub oil - changeSpark plug/electrode gap - replacementAir filter - cleanIdling speed (*) - adjustmentCylinder cooling system - check/cleaningOil mixer/throttle linkage - adjustmentDriving belt - replacementVariable speed rollers - replacementMixer belt - replacementOdometer gear - greasingSteering - adjustmentBrake control levers - greasingBrake pads - check condition and wearFlexible brake tubes - replacementBrake fluid level - checkTransmission

WORKSHOP MANUAL Vespa LX 50 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important

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