MANUALE STAZIONE DI SERVIZIO - Vespa Club

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MANUALE STAZIONE DI SERVIZIO665229 (IT), 665230 (EN), 665231 (FR), 665232 (DE),665233 (ES), 665234 (PT), 665235 (NL), 665236 (EL)Vespa LX 50 4valvole

MANUALESTAZIONE DISERVIZIOVespa LX 50 4valvoleThe 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)

MANUALE STAZIONE DISERVIZIOVespa LX 50 4valvoleQuesto manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalleofficine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questapubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base deiprincipi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioniimportanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verrannocomunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavorocompletamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è perquesto che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e ilcatalogo degli attrezzi specifici.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

CharacteristicsVespa LX 50 4valvoleRulesSafety 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 - 6

Vespa LX 50 4valvoleCharacteristicsVehicle identificationVEHICLE IDENTIFICATIONSpecificationChassis prefixEngine s and massCHAR - 7

Vespa LX 50 4valvoleCharacteristicsWEIGHT AND DIMENSIONSSpecificationDry weightWidthLengthWheelbaseMaximum heightDesc./Quantity102 5740 mm1755 mm1290 mm1140 mmEngineENGINESpecificationTypeBoreStrokeCubic capacityMAX PowerMAX torqueCompression ratioTiming systemDesc./Quantitysingle-cylinder, four-stroke and four-valve, air-cooled engine39 mm41.8 mm49,9 cm³3.2 kW at 8250 rpm3.8 Nm at 7750 rpm11.5 - 12.5 1single overhead camshaft, controlled by a chain on the lefthand side, three-arm rocking levers and pads calibrated forvalve clearance adjustment.1700 1900Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and50% unleaded petrol).electric starter/kick-starterengine lubrication with lobe pump (in the crankcase) driven bya chain. Mesh pre-filter and centrifugal on the crankshaftGravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor.intake 0.10 mmdischarge 0.15 mmvacuum KEIHIN NCV ø 20 with electronic control of carburation(SIS)forced air circulationEngine idle speedAir filterStarting systemLUBRICATIONFuel supplyValve clearance (cold engine)CARBURETTORCoolingOIL PUMPSpecificationTypeDistance between the rotorsAxial rotor clearanceDistance between the outer rotor and the pump bodyLevelnessDesc./QuantityTrochoidalAdmissible limit clearance: 0.15 mmLimit values admitted: 0.09 mmAdmissible limit clearance: 0.20 mm0.1 mmOIL FILTERSpecificationTypeDesc./Quantitymesh, plastic and centrifugal filter, before the oil pump and coaxially mounted onto the crankshaft keyed on the right sionCHAR - 8Desc./QuantityWith automatic expandable pulley variator, torque server, Vbelt, automatic clutch, gear reduction unit.

Vespa LX 50 tionEngine oilTransmission oilFuel tank (reserve)Desc./Quantity 850 cm³80 cm³ 8.5 l (2 l)Electrical systemWhen the advance check is carried out with a stroboscopic gun, add 10 flywheel keying to the tablebelow.ELECTRICAL COMPONENTS12345SpecificationIgnition advanceSpark plugBatteryFusesGeneratorDesc./Quantityreference in tableNGK ER9EH-N12V - 9AhOne 15A fuse - Two 7.5A fusessingle-phase alternating currentCHAR - 9

CharacteristicsCHECKING REMOTE CONTROLS «A» OPERATING AS CIRCUIT BREAKERS1) Check that, given regular conditions, there is nocontinuity between terminals 30 and 87.2) Apply 12V voltage to power terminals 85 and 86of the remote control.3) With the remote control powered, check thatthere is continuity between terminals 30 and 87.4) If these conditions are not fulfilled, the remotecontrol is damaged and must be replaced.TURN INDICATOR SWITCHKEY SWITCHLIGHT SWITCHCHAR - 10Vespa LX 50 4valvole

Vespa LX 50 4valvoleCharacteristicsSTARTER BUTTONHORN BUTTONSTOP BUTTONResistance between green cable and ground connection: approx. 170 OhmCHAR - 11

Vespa LX 50 4valvoleCharacteristics- Primary resistance: 0.5 0.6 Ohm- Resistance between primary and ground connection: infinite- Resistance between primary and HV output: 3 3.6 kOhm- Shielded cap: 5000 Ohm- Power: 120 W- resistance between BLUE cable and GROUNDCONNECTION: 1 OhmFrame and suspensionsCHASSIS AND SUSPENSIONSSpecificationTypeFRONT SUSPENSIONFront suspension strokeTrail (suspension rebounded/compressed)Rear suspensionRear suspension travel:Desc./QuantityStamped plate body with welded structural reinforcements.Single 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 mmBrakesFRENISpecificationFront brakeRear brakeDesc./QuantityØ 200-mm disc brake with hydraulic control activated by handlebar right-side lever.Ø 110-mm drum brake with mechanical control activated byhandlebar left-side lever.Wheels and tyresWHEELS AND TYRESSpecificationFront tyre sizeRear tyre sizeCHAR - 12Desc./Quantity110/70"-11"120/70-10"

Vespa LX 50 4valvoleCharacteristicsSpecificationFront tyre pressureRear tyre pressure:Light alloy rims (Front rim)Light alloy rims (rear rim)Desc./Quantity1.6 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.Carburettor50cc VersionKehinKEIHIN CARBURETTORSpecificationType:Throttle valve diameter:Diffuser diameterBody stamping:Maximum nozzle:Maximum air nozzle (on the body):Tapered pin stamped code:Throttle valve spring:Minimum nozzle:Minimum air nozzle (on the body):Initial minimum mix screw opening:Starter nozzle:Starter air nozzle (on the body):Stroke of starter pin:Desc./QuantityNCV 20Ø 20.5Ø 18.5AR3B72Ø2NNRA70 117 gr35Ø 1.81 3/442Ø 1.510.24 mmTightening TorquesSTEERING ASSEMBLYNameUpper steering ring nutSteering lower ring nutHandlebar lockingTorque in Nm30 408 1050 55 NmFRAME ASSEMBLYNameEngine-swinging arm boltFrame-swinging arm boltShock absorber - chassis nutShock absorber nut-engineRear wheel nutScrews fixing the odometer reel plateTorque in Nm33 4144 5220 2533 41104 1264 6FRONT SUSPENSIONNameShock absorber upper nutFront wheel axle nutShock absorber upper bracket boltsWheel rim screwsShock absorber lower bolts ( )Torque in Nm20 3075 9020 2520 2520 27( ) Lock these two bolts once the central upper nut of the shock absorber has been tightened.CHAR - 13

Vespa LX 50 4valvoleCharacteristicsN.B.FOR SAFETY LOCKS, SEE THE «PRE-DELIVERY» CHAPTER.FRONT 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 10ENGINE ASSEMBLYNameIgnition spark plug:Floating head cover screwsHead-cylinder stud bolt nutsScrews fixing head and cylinder to crankcaseChain tensioner pad screwTiming chain tensioner central screwCamshaft pulley screwRocking lever axle and camshaft bearing screwRocking levers adjusting nuts:Engine oil pre-filter cover:Engine oil drainage capFlywheel nutStator screwsPick-up screwsOil pump bulkhead screwTiming chain/oil pump compartment cover screwsOil decantation labyrinth sheet screwsOil pump crown screwScrews fixing oil pump to the crankcaseOil sump screwsInlet manifold screwCarburettor/manifold clamp screwScrews fixing cables to starter motorStarter screwsTransmission cover screwsStart-up lever screwCrankcase cooling cover screwClutch assembly nutCrankshaft pulley nutDriven pulley shaft nutHub oil drainage screwRear hub cap screwsCrankcase half union screwTorque in Nm10 15 Nm6 76 7 90 90 *8 105 7 Nm5 612 143 4 Nm7 9 Nm25 28 Nm25 2840 to 44 N.m3 43 44 54 57 88 105 68 10 Nm7 91.2 1.51.5 2.511 1311 1311 132 2.555 6018 to 20 90 Nm40 to 44 Nm3 5 Nm11 138 10* When assembling the new stud bolts, nut tightening involves 3 turns of 90 each after the first lockingat 6 7 Nm, consequently: 6 7 Nm 90 90 90 at criss-crossed sequences.Overhaul dataAssembly clearancesCHAR - 14

Vespa LX 50 4valvoleCharacteristicsCylinder - piston assy.COUPLING BETWEEN PISTON AND CYLINDERNameCylinderCylinderPistonPistonCylinder 1st oversizeCylinder 1st oversizePiston 1st oversizePiston 1st oversizeCylinder 2nd oversizeCylinder 2nd oversizePiston 2nd oversizePiston 2nd oversizeCylinder 3rd oversizeCylinder 3rd oversizePiston 3rd oversizePiston 3rd er38.993 39.00039.000 39.00739.007 39.01439.014 39.02139.193 39.20039.200 39.20739.207 39.21439.214 39.22139.393 39.40039.400 39.40739.407 39.41439.414 39.42139.593 39.60039.600 39.60739.607 39.61439.614 39.621Piston38.954 38.96138.961 38.96838.968 38.97538.975 38.98239.154 39.16139.161 39.16839.168 39.17539.175 39.18239.354 39.36139.361 39.36839.368 39.37539.375 39.38239.554 39.56139.561 39.56839.568 39.57539.575 39.582Play on fitting0.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.0460.032 0.046N.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 MARKFACING UPWARDS.- Measure the outside diameter of the gudgeonpin.CharacteristicPin outside diameter13 0 -0.004 mmMinimum admissible diameter gudgeon pin12.990 mmCHAR - 15

CharacteristicsVespa LX 50 4valvole- Measure the diameter of the bearings on the piston.CharacteristicPin seat diameter13 0.005 0.010 mm- Calculate the piston pin coupling clearance.N.B.THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENTMUST BE MADE ACCORDING TO THE PISTON AXIS.CharacteristicStandard clearance0.005 0.014 mm- Carefully clean the seal housings.- Measure the coupling clearance between thesealing rings and the grooves using suitable sensors, as shown in the diagram.- If the clearance is greater than that indicated inthe table, replace the piston.N.B.MEASURE THE CLEARANCE BY INSERTING THE BLADEOF THE FEELER THICKNESS GAUGE FROM THE SECONDSEAL SIDE.Fitting clearanceTop piston ring - standard coupling clearance0.03 0.065 mm Top piston ring - maximum clearance allowed after use 0.07 mm Middle pistonring - standard coupling clearance 0.02 0.055mm Middle piston ring - maximum clearance allowed after use 0.06 mm oil scraper ring - standard coupling clearance 0.04 0.16 mm oil scraperring - maximum clearance allowed after use0.17 mm- Using a bore meter, measure the inner cylinderdiameter at three different points according to thedirections shown in the figure.- Check that the coupling surface with the head isnot worn or misshapen.CHAR - 16

Vespa LX 50 4valvoleCharacteristics- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).CharacteristicMaximum allowable run-out:0.05 mmPiston rings- Alternately insert the three sealing rings into thecylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis.- Measure the opening, see figure, of the sealingrings using a thickness gauge.- If any measurements are greater than specified,replace the piston rings.N.B.BEFORE REPLACING ONLY THE PISTON RINGS, ENSURETHAT THE CLEARANCE BETWEEN THE PISTON RINGSAND THE PISTON RING GROOVES, AND BETWEEN THEPISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANYCASE, NEW PISTON RINGS USED IN COMBINATION WITHA USED CYLINDER MAY HAVE DIFFERENT BEDDINGCONDITIONS THAN THE STANDARD.SEAL RINGSName1st Compression ringDescriptionDimensions39 x 1InitialsAQuantity0.08 0.20CHAR - 17

Vespa LX 50 4valvoleCharacteristicsName2nd Compression ringOil scraper ring1st Compression ring1st Oversize2nd Compression ring1st OversizeOil scraper ring 1stOversize1st Compression ring2nd Oversize2nd Compression ring2nd OversizeOil scraper ring 2ndOversize1st Compression ring3rd Oversize2nd Compression ring3rd OversizeOil scraper ring 3rdOversizeDescriptionDimensions39 x 139 x 239.2 x 1InitialsAAAQuantity0.05 0.200.20 0.700.08 0.2039.2 x 1A0.05 0.2039.2 x 2A0.20 0.7039.4 x 1A0.08 0.2039.4 x 1A0.05 0.2039.4 x 2A0.20 0.7039.6 x 1A0.08 0.2039.6 x 1A0.05 0.2039.6 x 2A0.20 0.70Crankcase - crankshaft - connecting rodAXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKCASENameHalf-shaft, transmissionsideFlywheel-side half-shaftConnecting rodSpacer toolDescriptionDimensions14 0 -0.005InitialsA16 0 -0.00514.8 0.05 -045.00 / Fits and clearances D 0.15 0.30BCECharacteristicClearance between crankshaft and connecting rodA 0.15 0.30 mmCHAR - 18Quantity

Vespa LX 50 4valvoleCharacteristicsMeasure the bearings along X and Y axesCharacteristicCrankshaft bearing, transmission side20 -0.012 -0.025 mmCrankshaft bearing, flywheel side17 0.007 0 mm- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threadedtangs are in good working order.- In case of failures, replace the crankshaft.Specific tooling020074Y Support base for checking crankshaft alignmentCHAR - 19

CharacteristicsVespa LX 50 4valvole- Install the crankshaft on the support and measurethe displacement at the 4 points shown in the figure.N.B.IF VALUES OTHER THAN THOSE ALLOWED ARE DETECTED, TRY STRAIGHTENING THE CRANKSHAFT BY INSERTING A WOODEN WEDGE BETWEEN THE HALFSHAFTS OR BY CLOSING THEM WITH A VICE AS NEEDED. IF EVEN AFTER THIS OPERATION THE VALUES ARENOT THOSE ADMITTED, REPLACE THE CRANKSHAFT.CharacteristicOff-line maximum admitted - A0.15 mmOff-line maximum admitted - B0.02 mmOff-line maximum admitted - C0.02 mmOff-line maximum admitted - D0.10 mm- Using a bore gauge, measure the connecting rodsmall end diameter.N.B.IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OROVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE ANDCRANKSHAFT CHAPTER.CharacteristicRod small end diameter13 0.015 0.025 mmMax. diameter admitted: check the small end13.030 mmCalculate the coupling clearance between pin and rod small endCharacteristicPin - connecting rod clearance0.015 0.029 mmCylinder HeadBefore performing head service operations, thoroughly clean all coupling surfaces. Note the position ofthe springs and the valves so as not to change the original position during refittingCHAR - 20

Vespa LX 50 4valvoleCharacteristics- Using a trued bar check that the cylinder headsurface is not worn or distorted.- Check that the camshaft and rocking lever pinbearings show no signs of wear.- Check that the cylinder head cover surface, theintake manifold and the exhaust manifold are notworn.- It is advisable to replace the head if any failure isfound.CharacteristicMaximum allowable run-out:0.1 mm- Insert the valves into the cylinder head.- Alternatively check the intake and exhaustvalves.- The test is carried out by filling the manifold withpetrol and checking that the head does not oozethrough the valves when these are just pressedwith the fingers.Measure the camshaft bearing seats and rockinglever support pins with a bore meterHEAD CHECKSpecificationStandard diameter (mm) AStandard diameter (mm) BStandard diameter (mm) CDesc./QuantityØ 32.015 32.025 mmØ 16.0 16.018Ø 11.0 11.018CHAR - 21

Vespa LX 50 4valvoleCharacteristicsMeasure the unloaded spring length. Standard length: 31.3 mm Admissible limit after use: 29.3- Clean the valve seats of any carbon residues.- Using the Prussian blue, check the width of theimpression on the valve seat "V".CharacteristicStandard value:1 - 1.3 mmAdmissible limit:1.6 mm- If the impression width on the valve sea

Vespa LX 50 4valvole Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei

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