Vespa LXV125 Workshop Manual

Vespa LXV125 Workshop Manual
Service station manual
633852 IT - 633853 EN - 633854 FR - 633855 DE 633856 ES - 633857 PT - 633858 NL - 633859 EL
LXV 125
Service station
manual
LXV 125
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
versions should be checked at the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
Service station manual
LXV 125
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It
is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical
principles and vehicle repair technique procedures. Any 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 relating to 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 completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol 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
SUSPENSIONS
SUSP
BRAKING SYSTEM
CHASSIS
PRE-DELIVERY
TIME
BRAK SYS
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
LXV 125
Rules
This 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. 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.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling
members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 6
LXV 125
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification
Engine prefix
Chassis prefix
Desc./Quantity
ZAP M444M
ZAP M443010000÷0000
Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification
Kerb weight
Overall height
Width
Wheelbase
Length
Desc./Quantity
114 ± 5 kg
1180 mm
740 mm
1280 mm
1800 mm
CHAR - 7
LXV 125
Characteristics
Engine
ENGINE
Specification
Engine
Timing system
Valve clearance
Bore x stroke
Cubic capacity
Carburettor
Engine idle speed
Start-up
Max power to the shaft
Cooling
Desc./Quantity
Single-cylinder, 4-stroke Piaggio LEADER
Single overhead camshaft (SOHC) with 2 valves
intake 0.10
outlet 0.15
57.0 x 48.6 mm
124 cc
KEIHIN CVK26
1650 ± 100 rpm
Electric
10.5 CV at 8250 rpm
Forced air circulation.
Transmission
TRANSMISSION
Specification
Transmission
Desc./Quantity
With automatic expandable pulley variator with torque server,
V belt, automatic clutch, gear reduction unit and transmission
housing with forced air circulation cooling.
Capacities
CAPACITY
Specification
Engine oil
Rear hub oil
Fuel tank capacity
Desc./Quantity
61 in³ (1,000 cm³)
~ 100 cm³
~ 8.5 litres (2 l of which is reserve)
Electrical system
ELECTRICAL SYSTEM
Specification
Start-up
Spark plug
Desc./Quantity
Electric
Champion RG6YC- NGK CR7EB
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Chassis
Steering and suspensions
CHAR - 8
Desc./Quantity
Unitised body made of stamped plate.
Steering tube articulated on the front wheel carrier hub; helicoidal spring suspension and double-acting hydraulic shock
absorber; rear with double-acting shock absorber and coaxial
spring adjustable to 4 positions at preloading.
LXV 125
Characteristics
Brakes
BRAKES
Specification
Front brake
Desc./Quantity
Disc brake (Ø 200 mm) with hydraulic control (lever on the far
right of the handlebar) and fixed calliper.
Ø110 mm drum brake
Rear brake
Wheels and tyres
WHEELS AND TYRES
Specification
Front wheel rim
Front tyre
Rear wheel rim
Rear tyre
Front tyre pressure
Rear tyre pressure
Rear wheel pressure (rider and passenger):
Desc./Quantity
Die-cast aluminium alloy; 2.50 x11"
Tubeless; 110/70-11"
Die-cast aluminium alloy; 3.00 x 10"
Tubeless; 120/70-10"
1.6 bar
2 bar
2.3 bar
Carburettor
CARBURETTOR SETTING
Specification
Type
Body stamping
Throttle valve diameter
Diffuser diameter
Maximum jet
Maximum air jet (on the body)
Tapered pin stamping
Throttle valve spring
Minimum jet
Idle air jet (on the body)
Idle mixture adjustment screw initial opening
Starter jet
Starter air jet (on the body)
Starter pin travel
Starter resistance
Desc./Quantity
CVEK26
CVK
Ø 26.5
Ø 26.4
82
85
NELA
130 ÷ 180 gr.
35
150
2
42
Ø 1.5
10 mm (at 24°)
20 Ohm (at 24°)
Kehin
CARBURETTOR SETTING
Specification
Type
Body stamping
Throttle valve diameter
Diffuser diameter
Maximum jet
Maximum air jet (on the body)
Tapered pin stamping
Throttle valve spring
Minimum jet
Idle air jet (on the body)
Idle mixture adjustment screw initial opening
Starter jet
Starter air jet (on the body)
Desc./Quantity
CVEK26
CVK
Ø 26.5
Ø 26.4
82
85
NELA
130 ÷ 180 gr.
35
150
2
42
Ø 1.5
CHAR - 9
LXV 125
Characteristics
Specification
Starter pin travel
Starter resistance
Desc./Quantity
10 mm (at 24°)
20 Ohm (at 24°)
Tightening Torques
LUBRICATION
Name
Hub oil drainage cap
Oil filter
Oil pump cover screws
Oil pump screws
Pump control pulley screw
Chain cover screws
Oil sump screws
Minimum oil pressure sensor
Blow-by recovery duct fixing screws
Torque in Nm
15 ÷ 17
4÷6
5-6
5-6
10 ÷ 14
4÷6
10 ÷ 14
12 ÷ 14
3-4
HEAD AND CYLINDER
Name
Ignition spark plug
Head cover screws
Nuts fixing head to cylinder (*)
Head fixing screws (external)
Starter ground screw
Flywheel cover screw
Flywheel air manifold screw
Pressure reducer counterweight retainer
Camshaft pulley screw
Timing chain tensioner slider screw
Starter ground support screw
Tensioner screws
Timing chain tensioner central screw
Camshaft retention plate screw
Nut fixing muffler to cylinder head
Head intake manifold screw
Torque in Nm
12 ÷ 14
11 ÷ 13
28 ÷ 30
11 ÷ 13
7 ÷ 8.5
1÷2
3÷4
7 ÷ 8.5
12 ÷ 14
10 ÷ 14
11 ÷ 15
11 ÷ 13
5-6
5-6
16 ÷ 18
11 ÷ 13
TRANSMISSION
Name
Drive pulley nut
Transmission cover screw
Driven pulley shaft nut
Rear hub cap screw
Clutch unit nut on driven pulley
Torque in Nm
75 ÷ 83
11 ÷ 13
54 ÷ 60
24 ÷ 27
45 ÷ 50
FLYWHEEL
Name
Flywheel fan screws
Stator assembly screws (°)
Flywheel nut
Pick-up screw
Torque in Nm
3÷4
3÷4
52 ÷ 58
3÷4
(°) Apply LOCTITE 243 threadlock
CRANKCASE AND CRANKSHAFT
Name
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
Oil filter on crankcase fitting
Rear brake cam tightening screw
Engine-crankcase coupling screws
Pre-filter cap
CHAR - 10
Torque in Nm
4÷6
27 ÷ 33
11 ÷ 13
11 ÷ 13
24 ÷ 30
LXV 125
Characteristics
Name
Starter motor fixing screw
Muffler to crankcase fixing screws
Engine oil drainage cap
Torque in Nm
11 ÷ 13
24 ÷ 27
24 ÷ 30
STEERING ASSEMBLY
Name
Steering upper ring nut
Lower steering ring nut
Handlebar fixing screw
Torque in Nm
35 ÷ 40
12 - 14
50 ÷ 55
FRAME ASSEMBLY
Name
Swinging arm pin - frame
Engine-swinging arm bolt
Stand bolt
Swinging arm silent-block containment bolt
Torque in Nm
44 ÷ 52
33 ÷ 41
32 ÷ 40
33 ÷ 41
FRONT SUSPENSION
Name
Shock absorber upper nut
Front wheel axle nut
Shock absorber upper bracket bolts
Wheel rim screws
Shock absorber lower bolts (°)
Torque in Nm
20 ÷ 30
75 ÷ 90
20 ÷ 25
20 ÷ 25
20 ÷ 27
FRONT BRAKE
Name
Brake fluid pump-hose fitting
Brake fluid pipe-calliper fitting
Screw tightening calliper to the support
Brake disc screw
Oil bleed valve (on the calliper)
Handlebar pump
Torque in Nm
8 ÷ 12
20 ÷ 25
20 ÷ 25
5 ÷ 6.5
10 ÷ 12
7 ÷ 10
REAR SUSPENSION
Name
Rear wheel axle
Lower shock absorber clamp
Shock absorber/frame nut:
Torque in Nm
104 ÷ 126
33 ÷ 41
20 ÷ 25
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST-IRON LINER
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st increase
Coupling 1st increase
Coupling 1st increase
Coupling 1st increase
Initials
A
B
C
D
A1
B1
C1
D1
Cylinder
56.980 ÷ 56.987
56.987 ÷ 56.994
56.994 ÷ 57.001
57.001 ÷ 57.008
57.180 ÷ 57.187
57.187 ÷ 57.194
57.194 ÷ 57.201
57.201 ÷ 57.208
Piston
56.933 ÷ 56.940
56.940 ÷ 56.947
56.947 ÷ 56.954
56.954 ÷ 56.961
57.133 ÷ 57.140
57.140 ÷ 57.147
57.147 ÷ 57.154
57.154 ÷ 57.161
Play on fitting
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
CHAR - 11
LXV 125
Characteristics
Name
Coupling 2nd increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
A2
B2
C2
D2
A3
B3
C3
D3
Cylinder
57.380 ÷ 57.387
57.387 ÷ 57.394
57.394 ÷ 57.401
57.401 ÷ 57.408
57.580 ÷ 57.587
57.587 ÷ 57.594
57.594 ÷ 57.601
57.601 ÷ 57.608
Piston
57.333 ÷ 57.340
57.340 ÷ 57.347
57.347 ÷ 57.354
57.354 ÷ 57.361
57.533 ÷ 57.540
57.540 ÷ 57.547
57.547 ÷ 57.554
57.554 ÷ 57.561
Play on fitting
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
PISTON TO CAST IRON CYLINDER COUPLING
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
M
N
O
P
M1
N1
O1
P1
M2
N2
O2
P2
M3
N3
O3
P3
Cylinder
56.997 ÷ 57.004
57.004 ÷ 57.011
57.011 ÷ 57.018
57.018 ÷ 57.025
57.197 ÷ 57.204
57.204 ÷ 57.211
57.211 ÷ 57.218
57.218 ÷ 57.225
57.397 ÷ 57.404
57.404 ÷ 57.411
57.411 ÷ 57.418
57.418 ÷ 57.425
57.597 ÷ 57.604
57.604 ÷ 57.611
57.611 ÷ 57.618
57.618 ÷ 57.625
Piston
56.944 ÷ 56.951
56.951 ÷ 56.958
56.958 ÷ 56.965
56.965 ÷ 56.972
57.144 ÷ 57.151
57.151 ÷ 57.158
57.158 ÷ 57.165
57.165 ÷ 57.172
57.344 ÷ 57.351
57.351 ÷ 57.358
57.358 ÷ 57.365
57.365 ÷ 57.372
57.544 ÷ 57.551
57.551 ÷ 57.558
57.558 ÷ 57.565
57.565 ÷ 57.572
Play on fitting
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
Dimensions
57 x 1
57x1
57x2.5
57.2 x 1
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.10 ÷ 0.35
0.15 ÷ 0.30
57.2x1
A
0.10 ÷ 0.30
57.2x2.5
A
0.10 ÷ 0.35
57.4x1
A
0.15 ÷ 0.30
57.4x1
A
0.10 ÷ 0.30
57.4x2.5
A
0.10 ÷ 0.35
57.6x1
A
0.15 ÷ 0.30
57.6x1
A
0.10 ÷ 0.30
57.6x2.5
A
0.10 ÷ 0.35
Piston rings
SEAL RINGS
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring 1st
oversize
Oil scraper ring 1st
oversize
Oil scraper ring 1st
oversize
Compression ring 2nd
oversize
Oil scraper ring 2nd
oversize
Oil scraper ring 2nd
oversize
Compression ring 3rd
oversize
Oil scraper ring 3rd
oversize
Oil scraper ring 3rd
oversize
Description
Maximum clearance after use: 1 mm
CHAR - 12
LXV 125
Characteristics
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Half-shaft, transmission
side
Flywheel-side half-shaft
Connecting rod with PP
Crank pin width
Description
Dimensions
16.6 +0-0.05
Initials
A
Quantity
D = 0.20 - 0.50
16.6 +0-0.05
18 -0.10 -0.15
51.400
B
C
E
D = 0.20 - 0.50
0.20 ÷ 0.50
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft category 1 Crankcase category 1
Crankshaft category 1 Crankcase category 2
Crankshaft category 2 Crankcase category 1
Crankshaft category 2 Crankcase category 2
Description
Dimensions
Initials
Category 1
Class 2
Category 1
Category 2
Category B - blue
Type C - yellow
Category E - green
E-E
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.953 ÷ 32.959
32.959 ÷ 32.965
1.973 ÷ 1.976
1.976 ÷ 1.979
1.979 ÷ 1.982
C-C
C-C
B-B
Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40
CHAR - 13
LXV 125
Characteristics
Slot packing system
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool
- Set the dial gauge to zero at a contrast plane with an average precharge, for example 5 mm. Keeping
the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.
- Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation)
- Calculate the difference between the two measurements: use the chart below to identify the thickness
of the cylinder base gasket to be used for refitting. The proper identification of the cylinder base gasket
thickness allows maintaining the correct compression ratio.
- Remove the special tool and the cylinder.
Characteristic
Compression ratio (125)
10.6 : 1
SHIMMING SYSTEM
Specification
Value measured
Thickness
Value measured
Thickness
Value measured
Thickness
CHAR - 14
Desc./Quantity
0 ÷ 0.1
0.8 ± 0.05
0.1 ÷ 0.3
0.6 ± 0.05
0.3 - 0.4
0.4 ± 0.05
LXV 125
Characteristics
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP ROTRA 80W-90
Description
Rear hub oil
AGIP BRAKE 4
AGIP CITY HI TEC 4T
Brake fluid
Oil to lubricate flexible transmissions
(brakes, throttle control and odometer)
Oil for air filter sponge
AGIP FILTER OIL
AGIP CITY HI TEC 4T
AGIP GREASE MU3
AGIP GP 330
Specifications
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
FMVSS DOT 4 Synthetic fluid
Oil for 4-stroke engines
Mineral oil with specific additives for increased adhesiveness
Engine oil
SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
Grease for odometer transmission gear Soap-based lithium grease with NLGI 3;
case
ISO-L-XBCHA3, DIN K3K-20
Grease for brake control levers, throttle,
White calcium complex soap-based
stand
spray grease with NLGI 2; ISO-L-XBCIB2
CHAR - 15
INDEX OF TOPICS
TOOLING
TOOL
LXV 125
Tooling
APPROPRIATE TOOL
Stores code
001330Y
Description
Tool for fitting steering seats
001467Y009
Driver for OD 42-mm bearings
001467Y013
Pliers to extract ø 15-mm bearings
002465Y
Pliers for circlips
005095Y
Engine support
008564Y
Flywheel extractor
TOOL - 17
LXV 125
Tooling
TOOL - 18
Stores code
020004Y
Description
Punch for removing fifth wheels from
headstock
020055Y
Wrench for steering tube ring nut
020074Y
Support base for checking crankshaft
alignment
020150Y
Air heater support
020151Y
Air heater
020193Y
Oil pressure gauge
LXV 125
Tooling
Stores code
020262Y
Description
Crankcase splitting strip
020263Y
Sheath for driven pulley fitting
020287Y
Clamp to assemble piston on cylinder
020306Y
Punch for assembling valve seal rings
020329Y
MityVac vacuum-operated pump
020330Y
Stroboscopic light to check timing
TOOL - 19
LXV 125
Tooling
TOOL - 20
Stores code
020331Y
Description
Digital multimeter
020332Y
Digital rev counter
020333Y
Single battery charger
020334Y
Multiple battery charger
LXV 125
Tooling
Stores code
020335Y
Description
Magnetic support for dial gauge
020357Y
020359Y
32 x 35 mm adaptor
42x47-mm adaptor
020360Y
Adaptor 52 x 55 mm
020363Y
20 mm guide
020364Y
25-mm guide
TOOL - 21
LXV 125
Tooling
TOOL - 22
Stores code
020368Y
Description
driving pulley lock wrench
020375Y
Adaptor 28 x 30 mm
020376Y
Adaptor handle
020382Y011
adapter for valve removal tool
020409Y
Multimeter adaptor - Peak voltage detection
LXV 125
Tooling
Stores code
020412Y
Description
15 mm guide
020414Y
28-mm guide
020423Y
driven pulley lock wrench
020424Y
Driven pulley roller casing fitting punch
020425Y
Punch for flywheel-side oil seal
020426Y
Piston fitting fork
TOOL - 23
LXV 125
Tooling
TOOL - 24
Stores code
020427Y
Description
Piston fitting band
020428Y
Piston position check support
020430Y
Pin lock fitting tool
020431Y
Valve oil seal extractor
020434Y
Oil pressure control fitting
020444Y
Tool for fitting/ removing the driven pulley
clutch
LXV 125
Tooling
Stores code
020565Y
Description
Flywheel lock calliper spanner
020622Y
Transmission-side oil guard punch
TOOL - 25
INDEX OF TOPICS
MAINTENANCE
MAIN
LXV 125
Maintenance
Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change
EVERY 3000 KM
Action
Engine oil - level check/ top-up
AFTER 1000 KM
80'
Action
Engine oil - replacement
Hub oil - change
Oil filter (net filter) - clean
Idle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 6000 KM, 18000 KM, 54000 KM
150'
Action
Engine oil - replacement
Hub oil level - check
Spark plug electrode gap - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Variable speed rollers/pads - check
Driving belt - checking
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
AFTER 12000 KM, 60000 KM
160'
Action
Engine oil - replacement
Hub oil level - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
MAIN - 27
LXV 125
Maintenance
Action
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Centre stand - lubrication
Secondary air filter - cleaning
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 24000 KM AND AFTER 48000 KM
205'
Action
Engine oil - replacement
Hub oil - change
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Cylinder ventilation system - cleaning
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Secondary air filter - cleaning
Centre stand - lubrication
Vehicle and brake test - road test
(*) See instructions in «Idle speed adjustment» section
AT 30000 KM, AT 42000 KM AND AT 66000 KM
125'
Action
Engine oil - replacement
Hub oil level - check
Spark plug electrode gap - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Slide pads and variator rollers - check
Driving belt - checking
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
MAIN - 28
LXV 125
Maintenance
AFTER 36000 KM
300'
Action
Engine oil - replacement
Hub oil - change
Spark plug - replacement
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Flexible brake tubes - replacement
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Secondary air filter - cleaning
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in «Idle speed adjustment» section
AFTER 72,000 KM
300'
Action
Engine oil - replacement
Hub oil - change
Spark plug - replacement
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Cylinder ventilation system - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Flexible brake tubes - replacement
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Secondary air filter - cleaning
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in «Idle speed adjustment» section
MAIN - 29
Maintenance
Checking the spark advance
The ignition advance is determined electronically
on the basis of parameters known by the control
unit. For this reason it is not possible to interpret
the reference values based on the engine rpm.
The ignition advance value is detectable at any
time using the diagnostic tester. It is possible to
check whether the ignition advance determined by
the injection system matches the value actually
activated on the engine, by means of the stroboscopic light.
Proceed as follows:
- Remove the spark plug.
- Remove the plastic cover on the flywheel cover
shown in the photograph.
- Remove the transmission compartment air intake
cover shown in the photograph.
- Rotate the driving pulley fan using a screwdriver
until the reference marks between the flywheel
and flywheel cover coincide as shown in the photograph.
- Bring the reference mark onto the transmission
side between the fan and the transmission cover
as shown in the photograph.
- Refit the spark plug.
- Refit the plastic cap on the flywheel cover.
- Adjust the spark gap to the contact position (no
reference mark visible) and install it on engine between the spark plug and spark plug cap
- Connect the induction clamp on the spark gap
cable respecting the proper polarity (the arrow on
the clamp must be pointing at the spark plug).
- Connect the diagnostic tester.
- Start the engine.
- Select the «parameter» function in this menu.
MAIN - 30
LXV 125
LXV 125
Maintenance
- Select the stroboscopic light command in the traditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diagnostic tester.
If the values do not correspond, check:
- distribution timing
- rpm-timing sensor
- injection control unit
Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light to check timing
020621Y HV cable extraction adaptor
- To check ignition advance, use the stroboscopic light with induction pincers connected to the spark
plug power wire.
- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the
pincers must be pointing at the spark plug).
- Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines).
- Start the engine and check that the light works properly and the rpm indicator can read also the high
rpm (e.g. 8000 rpm).
- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive
load on the spark plug power line (10 ÷ 15 KΩ in series to HV wire).
MAIN - 31
LXV 125
Maintenance
- Operating on the flash bulb phase difference calibrator, make the reference on the flywheel cover
coincide with the fan reference as shown in the
photograph. Read the advance degrees indicated
by the stroboscopic light and compare them with
those specified.
Characteristic
Ignition advance check
10° ± 1° at 1650 rpm
Spark advance variation
REVOLUTION LIMITER
Specification
Operation threshold
Reactivation threshold
Spark elimination
Braking system
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
MAIN - 32
Desc./Quantity
First threshold : 9300 ± 50
Second threshold : 9800 ± 50
First threshold : 8850 ± 50
Second threshold : 9350 ± 50
First threshold : 10 sparks on 15
Second threshold : 15 sparks on 15
LXV 125
Maintenance
Top-up
Proceed as follows:
- Remove the tank cap by loosening the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maximum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR
EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS,
IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID
EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY
USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID
MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Headlight adjustment
Proceed as follows:
1. Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the borderline of the projected light beam on the screen
is not lower than 9/10 of the distance from the
MAIN - 33
Maintenance
ground to the centre of vehicle headlamp and higher than 7/10;
3. If it is, loosen the headlight support fixing screws
and adjust the headlight direction.
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS USED.
SAS filters inspection and cleaning
Proceed as follows:
- Remove the right-hand side fairing
- Remove the screw on the rear part, to the right
of the footrest, indicated in the photograph
- Remove the spoiler terminal
- Remove the screw fixing the SAS valve to the
flywheel cover, indicated in the photograph.
MAIN - 34
LXV 125
LXV 125
Maintenance
- Remove the 6 flywheel cover screws indicated in
the photograph and remove the flywheel cover.
- Remove the filter indicated in the photograph
- Check that the gasket is in good conditions
- Check the SAS filter housing for dents or deformations
- Clean the SAS filter carefully. Replace the filter if
it is damaged or deformed.
To refit, carry out the removal operations but in reverse order.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER
MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE
SCHEDULED MAINTENANCE CHART.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY
AIR FILTER
MAIN - 35
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
LXV 125
Troubleshooting
Engine
Poor performance
POOR PERFORMANCE
Possible Cause
Air filter blocked or dirty.
Fuel nozzles or cock clogged or dirty
Dirty or faulty vacuum-operated cock
Failing automatic starter on the carburettor
Excessive driving belt wear
Lack of compression: parts, cylinder and valves worn
Oil level exceeds maximum
Excess of encrustations in the combustion chamber
Incorrect timing or worn timing system elements
Muffler obstructed
Inefficient automatic transmission
Wrong valve adjustment
Overheated valves
Valve seat distorted
Worn cylinder, Worn or broken piston rings
Operation
Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to
drip dry and then reassemble.
Dismantle, wash with solvent and dry with compressed air
Check the filter on the cock, remove the petrol and wash the
tank, if necessary. Replace the cock as a last resource.
Check the electrical wiring and mechanical movement, replace
if necessary.
Check it and replace, if necessary
Replace the worn parts
Check for causes and fill to reach the correct level
Descale the cylinder, the piston, the head and the valves
Time the system again or replace the worn parts
Replace
Check the rollers and the pulley movement, replace the damaged parts and lubricate the driven pulley moveable guide with
Montblanc Molybdenum Grease
Adjust the valve clearance properly
Remove the head and the valves, grind or replace the valves
Replace the head assembly
Replace the piston cylinder assembly or just the piston rings
Rear wheel spins at idle
REAR WHEEL ROTATES WITH ENGINE AT IDLE
Possible Cause
Idling rpm too high
Clutch fault
Operation
Adjust the idle speed
Check the springs / clutch masses
Starting difficulties
DIFFICULTY STARTING UP
Possible Cause
Battery flat
Faulty spark plug or incorrect ignition advance
- Engine flooded.
Incorrect valve sealing or valve adjustment
Rpm too low at start-up or engine and start-up system damaged
Altered fuel characteristics
Vacuum operated cock failure
Operation
Check the state of the battery. If it shows signs of sulphation
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
Replace the spark plug or check the ignition circuit components
Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the motor turn so as to expel the fuel excess taking care to
connect the cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Inspect the head and/or restore the correct clearance
Check the starter motor and the kick-starter unit
Drain off the fuel no longer up to standard; then, refill
Check that fuel is adequately supplied through the pipe by applying a vacuum to the suction pipe
TROUBL - 37
LXV 125
Troubleshooting
Possible Cause
Failing automatic starter on the carburettor
Start-up enabling buttons failure
Carburettor nozzles clogged or dirty
Air filter obstructed or dirty.
Operation
Check the electrical wiring and mechanical movement, replace
if necessary.
Check continuity using an Ohm meter, with the switch pressed;
replace if necessary
Dismantle, wash with solvent and dry with compressed air
Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to
drip dry and then reassemble.
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause
Worn valve guides
Worn valve oil guard
Oil leaks from the couplings or from the gaskets
Worn or broken piston rings or piston rings that have not been
fitted properly
Operation
Check and replace the head unit if required
Replace the valve oil guard
Check and replace the gaskets or restore the coupling seal
Replace the piston cylinder unit or just the piston rings
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE
Possible Cause
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Perform the dimensional checks on the oil pump components
Replace the cartridge filter
Restore the level using the recommended oil type (Selenia HI
Scooter 4 Tech)
Engine tends to cut-off at full throttle
THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE
Possible Cause
Maximum jet clogged
Water or condensate in the carburettor tank
Level in tank too low
Operation
Remove the carburettor, wash with solvent and dry with compressed air
Remove the tank, wash with solvent and dry with compressed
air
Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Engine tends to cut-off at idle
THE ENGINE TENDS TO STOP AT IDLE SPEED
Possible Cause
Incorrect idle adjustment
Incorrect timing
The starter remains on
Faulty spark plug or incorrect ignition advance
Pressure too low at the end of compression
Minimum nozzle dirty
TROUBL - 38
Operation
Adjust using the rpm indicator
Time the system and check the timing system components
Check: electric wiring, circuit not interrupted, mechanical
movement and power supply; replace if necessary
Replace the spark plug or check the ignition circuit components
Check the thermal group seals and replace worn components
Wash the nozzle with solvent and dry with compressed air
LXV 125
Troubleshooting
High fuel consumption
EXCESSIVE FUEL CONSUMPTION
Possible Cause
Air filter blocked or dirty.
Starter inefficient
Operation
Clean according to the procedure
Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Check the maximum and minimum nozzles are adequately
fixed in their fittings
Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Loose nozzles
Incorrect float level
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Slippage or irregular functioning
Operation
Check that there is no grease on the masses.
Check that the faying surface between the clutch masses and
the clutch bell is mainly in the middle and with equivalent specifications on the three masses.
Check that the clutch bell is not scored or worn abnormally
Never run the engine without the clutch bell
Insufficient braking
INEFFICIENT OR NOISY BRAKING
Possible Cause
Worn brake pads or shoes
Front brake disk loose or deformed
Air bubbles inside the hydraulic braking system
Fluid leakage in hydraulic braking system
Excessive backlash in the rear brake control cable
Operation
Replace the brake pads or shoes and check for brake disk or
drum wear conditions.
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.
Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Failing elastic fittings, plunger or brake pump seals, replace
Adjust the backlash with the appropriate adjuster located on
the back part of the crankcase.
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Rubber gaskets swollen or stuck
Compensation holes on the pump clogged
Brake disc slack or distorted
Defective piston sliding
Operation
Replace gaskets.
Clean carefully and blast with compressed air
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.
Check calliper and replace any damaged part.
TROUBL - 39
LXV 125
Troubleshooting
Electrical system
Battery
BATTERY
Possible Cause
Battery
Operation
The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. If the
vehicle is not used for some time (1 month or more) the battery
needs to be recharged periodically. The battery runs down
completely in the course of 5 ÷ 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keeping in mind that the black ground wire is connected to the
negative terminal while the red wire is connected to the terminal
marked+. Follow the instructions in the ELECTRICAL SYSTEM
chapter for the recharging of the batteries.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING
Possible Cause
Electronic ignition device failure
Operation
With the key switch set to "ON" jump the contacts 1 (BlueBlack) and 5 (Orange) on the control unit connector.
If by operating the turn indicator control the lights are not steadily on, replace the control unit; otherwise, check the cable
harness and the switch.
Steering and suspensions
Heavy steering
STEERING HARDENING
Possible Cause
Steering hardening
Operation
Check the tightening of the top and bottom ring nuts. If irregularities in turning the steering continue even after making the
above adjustments, check the seats on which the ball bearings
rotate: replace them if they are recessed or if the balls are flattened.
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
Excessive steering backlash
TROUBL - 40
Operation
Check the tightening of the top ring nut. If irregularities continue
in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.
LXV 125
Troubleshooting
Noisy suspension
NOISY SUSPENSION
Possible Cause
Noisy suspension
Operation
If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition.
Finally, check the locking torque of the wheel axle nut, the
brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber
work properly.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION
Possible Cause
Oil leakage from suspension
Operation
Replace the damper.
TROUBL - 41
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
LXV 125
Electrical system
LEGENDA (Con pompa elettrica):
1. Dispositivo di accensione elettronica
2. Antenna immobilizer
3. Sensore di temperatura esterna
4. Volano magnete - Pick-up
5. Deviatore arresto motore
6. T.P.S.
7. Riscaldatore carburatore
8. Starter automatico
9. Commutatore a chiave
10. Regolatore di tensione
11. Fusibili principali
12. Batteria
13. Motorino di avviamento
14. Teleruttore di avviamento
15. Pulsante di avviamento
16. Pulsante di stop sul freno posteriore
17. Fusibili secondari
18. Pulsante di stop sul freno anteriore
19. Commutatore lampeggiatori
ELE SYS - 43
Electrical system
20. Clacson
21. Pulsante clacson
22. Lampada illuminazione targa
23. Indicatore di direzione posteriore sinistro
24. Lampada luce di stop e di posizione posteriore
25. Indicatore di direzione posteriore destro
26. Indicatore di direzione anteriore sinistro
27. Proiettore completo
A. Lampada per luce di posizione
B. Lampada per luce abbagliante e anabbagliante
28. Indicatore di direzione anteriore destro
29. Sensore pressione olio
30. Gruppo strumenti
A. Spia indicatori di direzione
B. Spia luce abbagliante
C. Spia riserva carburante
D. Spia pressione olio
E. Spia immobilizer
31. Predisposizione spia acustica indicatori di direzione
32. Trasmettitore livello carburante
33. Relé luce anabbagliante
34. Relé luce abbagliante
35. Deviatore luci con sprazzo
36. Pompa carburante
37. Dispositivo di gestione pompa
1. +Chiave
3. Massa pompa
4. +Pompa
5. Massa
6. Giri motore
38. Presa per diagnostica
39. Bobina A.T.
40. Candela
ELE SYS - 44
LXV 125
LXV 125
Electrical system
KEY:
1. Magneto flywheel
2. Electronic ignition device
3. Immobilizer aerial
4. Diagnostics socket
5. TPS potentiometer
6. Voltage regulator
7. Key switch
8 Engine stop switch
9. Automatic starter
10. Carburettor heater
11. Fuse-box
12. Battery
13. Starter motor
14. Starter remote control
15. Starter button
16. Fuel pump
17. Fuse-box
18. STOP button on front brake
19. STOP button on rear brake
ELE SYS - 45
Electrical system
LXV 125
20. Turn indicator switch
21. Left turn rear indicator lamp
22. Rear headlight assembly with tail light/stop light bulb
23. License plate bulb
24. Right turn rear indicator lamp
25. Light switch
26. Left turn front indicator lamp
27. Front headlight assembly with high-/low-beam light bulb
28. Right turn front indicator lamp
29. High-beam light remote control
30. Low-beam light remote control
31. Fuel level warning light control
32. Low oil warning light control
33. Instrument panel
34. Horn button
35. Horn
36. Turn indicator sound alarm wiring
37. Spark plug
38. High voltage coil
39. external temperature sensor
Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,
Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
Conceptual diagrams
ELE SYS - 46
LXV 125
Electrical system
Ignition
LEGENDA (Con pompa elettrica):
1. Dispositivo di accensione elettronica
2. Antenna immobilizer
5. Deviatore arresto motore
9. Commutatore a chiave
11. Fusibili principali
12. Batteria
39. Bobina A.T.
40. Candela
ELE SYS - 47
Electrical system
KEY:
1. Magneto flywheel
2. Electronic ignition device
3. Immobilizer aerial
6. Voltage regulator
7. Key switch
8 Engine stop switch
11. Fuse-box
12. Battery
37. Spark plug
38. High voltage coil
ELE SYS - 48
LXV 125
LXV 125
Electrical system
Headlights and automatic starter section
LEGENDA (Con pompa elettrica):
1. Dispositivo di accensione elettronica
5. Deviatore arresto motore
7. Riscaldatore carburatore
8. Starter automatico
9. Commutatore a chiave
11. Fusibili principali
12. Batteria
17. Fusibili secondari
22. Lampada illuminazione targa
24. Lampada luce di stop e di posizione posteriore
27. Proiettore completo
A. Lampada per luce di posizione
B. Lampada per luce abbagliante e anabbagliante
30. Gruppo strumenti
A. Spia indicatori di direzione
B. Spia luce abbagliante
C. Spia riserva carburante
ELE SYS - 49
Electrical system
D. Spia pressione olio
E. Spia immobilizer
33. Relé luce anabbagliante
34. Relé luce abbagliante
35. Deviatore luci con sprazzo
KEY:
2. Electronic ignition device
7. Key switch
9. Automatic starter
10. Carburettor heater
11. Fuse-box
12. Battery
17. Fuse-box
22. Rear headlight assembly with tail light/stop light bulb
23. License plate bulb
25. Light switch
27. Front headlight assembly with high-/low-beam light bulb
29. High-beam light remote control
30. Low-beam light remote control
ELE SYS - 50
LXV 125
LXV 125
Electrical system
33. Instrument panel
Battery recharge and starting
LEGENDA (Con pompa elettrica):
1. Dispositivo di accensione elettronica
4. Volano magnete - Pick-up
5. Deviatore arresto motore
9. Commutatore a chiave
10. Regolatore di tensione
11. Fusibili principali
12. Batteria
13. Motorino di avviamento
14. Teleruttore di avviamento
15. Pulsante di avviamento
16. Pulsante di stop sul freno posteriore
17. Fusibili secondari
18. Pulsante di stop sul freno anteriore
24. Lampada luce di stop e di posizione posteriore
ELE SYS - 51
Electrical system
KEY:
1. Magneto flywheel
6. Voltage regulator
7. Key switch
8 Engine stop switch
11. Fuse-box
12. Battery
13. Starter motor
14. Starter remote control
15. Starter button
17. Fuse-box
18. STOP button on front brake
19. STOP button on rear brake
22. Rear headlight assembly with tail light/stop light bulb
ELE SYS - 52
LXV 125
LXV 125
Electrical system
Level indicators and enable signals section
LEGENDA (Con pompa elettrica):
1. Dispositivo di accensione elettronica
2. Antenna immobilizer
3. Sensore di temperatura esterna
5. Deviatore arresto motore
6. T.P.S.
9. Commutatore a chiave
11. Fusibili principali
12. Batteria
17. Fusibili secondari
29. Sensore pressione olio
30. Gruppo strumenti
A. Spia indicatori di direzione
B. Spia luce abbagliante
C. Spia riserva carburante
D. Spia pressione olio
E. Spia immobilizer
32. Trasmettitore livello carburante
ELE SYS - 53
Electrical system
KEY:
2. Electronic ignition device
3. Immobilizer aerial
4. Diagnostics socket
5. TPS potentiometer
7. Key switch
11. Fuse-box
12. Battery
17. Fuse-box
31. Fuel level warning light control
32. Low oil warning light control
33. Instrument panel
39. external temperature sensor
ELE SYS - 54
LXV 125
LXV 125
Electrical system
Devices and accessories
LEGENDA (Con pompa elettrica):
1. Dispositivo di accensione elettronica
5. Deviatore arresto motore
9. Commutatore a chiave
11. Fusibili principali
12. Batteria
17. Fusibili secondari
19. Commutatore lampeggiatori
20. Clacson
21. Pulsante clacson
23. Indicatore di direzione posteriore sinistro
25. Indicatore di direzione posteriore destro
26. Indicatore di direzione anteriore sinistro
28. Indicatore di direzione anteriore destro
30. Gruppo strumenti
A. Spia indicatori di direzione
B. Spia luce abbagliante
C. Spia riserva carburante
ELE SYS - 55
Electrical system
D. Spia pressione olio
E. Spia immobilizer
31. Predisposizione spia acustica indicatori di direzione
36. Pompa carburante
37. Dispositivo di gestione pompa
1. +Chiave
3. Massa pompa
4. +Pompa
5. Massa
6. Giri motore
KEY:
2. Electronic ignition device
7. Key switch
8 Engine stop switch
11. Fuse-box
12. Battery
16. Fuel pump
17. Fuse-box
20. Turn indicator switch
21. Left turn rear indicator lamp
ELE SYS - 56
LXV 125
LXV 125
Electrical system
24. Right turn rear indicator lamp
26. Left turn front indicator lamp
28. Right turn front indicator lamp
33. Instrument panel
34. Horn button
35. Horn
36. Turn indicators sound alarm wiring
Checks and inspections
This section is devoted to the checks on the electrical system components.
Immobiliser
L'impianto di accensione elettronica viene gestito dalla centralina nella quale è integrato il sistema
Immobilizer. L'Immobilizer è un sistema antifurto che permette il funzionamento del veicolo solo se
questo viene avviato mediante delle chiavi codificate e riconosciute dalla centralina. Il codice è integrato
in un trasponder inserito nel corpo della chiave. Questo consente un funzionamento trasparente al
conducente che non deve eseguire alcuna operazione aggiuntiva alla normale rotazione della chiave.
L' impianto Immobilizer è composto dai seguenti componenti:
- centralina
- antenna immobilizer
- chiave master con trasponder incorporato (chiave rossa) con impugnatura grande
- chiave di servizio con trasponder incorporato (chiave nera) con impugnatura piccola
-bobina A.T.
-led diagnostico
Il led diagnostico svolge anche la funzione di lampeggio deterrente. Questa funzione si ottiene ogni
volta che il commutatore a chiave viene posizionato in "OFF" o se l'interruttore di arresto di emergenza
viene commutato in "OFF" e, al fine di non pregiudicare la carica della batteria, rimane attiva per 48
ore. Quando il commutatore a chiave viene posizionato in "ON" si interrompe la funzione di lampo
deterrente e di seguito avviene un lampo di conferma del passaggio in "ON". La durata di questo lampo
varia in funzione della programmazione della centralina. Nel caso in cui il led risulti spento indipendentemente dalla posizione del commutatore a chiave e/o non venga inizializzato il quadro strumenti,
verificare:
•
presenza tensione batteria
•
efficienza fusibile n° 1
•
presenza delle alimentazioni alla centralina come di seguito specificato:
Con interruttore chiave in OFF:
ELE SYS - 57
Electrical system
•
LXV 125
presenza tensione batteria fra i terminali 8-12 e terminale 8-massa telaio del connettore
grande (alimentazione fissa). Nel caso non vi fosse tensione verificare efficienza fusibile n
° 1 e relativo cablaggio.
Con interruttore chiave in ON, interruttore arresto emergenza motore in RUN:
•
presenza tensione batteria fra i terminali 9-12 e terminale 9-massa telaio del connettore
grande (alimentazione sotto quadro). Nel caso non vi fosse tensione verificare i contatti del
commutatore a chiave, efficienza fusibile n° 1 e relativo cablaggio. Verificare efficienza interruttore arresto di emergenza motore.
Virgin circuit
When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has been programmed properly. The data storage procedure for a previously not programmed control unit provides for the recognition of the master as the
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits
1 to 3 seconds).
- Insert the service 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.
During a single data storage sequence a maximum of 7 service keys are allowed.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, master key transponder, decoder and control unit are strictly
matched. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate
keys, you must repeat the procedure using all the keys you intend to keep using. If a service key should
become un-coded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In
any case it is advisable to use resistive spark plugs.
ELE SYS - 58
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Electrical system
Characteristic
MASTER key:
RED KEY
SERVICE key.
BLACK KEY
Diagnostic codes
The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During
this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at
the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the
led remains on permanently, it means the ignition
is inhibited:
1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be started but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transponder absent or cannot be used: The LED is permanently ON; in this condition, no operations are
possible, including starting 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 is displayed followed by the LED remaining off for 2 sec. and then by short 0.46 sec.
flashes the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
ELE SYS - 59
Electrical system
LXV 125
LED remains permanently OFF. The engine can
be started.
5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are:
•
Code 1 flash
•
2-flash code
•
3-flash code
Diagnostic code - 1 flash
The one-flash code indicates a system where the
serial line is not present or is not detected. Check
the Immobilizer aerial wiring and change it if necessary.
Diagnostic code - 2 flashes
A two-flash code shows a system where the control unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
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.
ELE SYS - 60
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Electrical system
Diagnostic code - 3 flashes
A three-flash code indicates a system where the
control unit does not recognise the key. Turn the
switch to ON using several keys: if the error code
is repeated even with the Master key, replace the
control unit. If this is not the case, perform a reprogramming.
Ignition circuit
All the control operations of the system that entail disconnecting cables (to check connections and the
devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls
might be irretrievably damaged.
The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected
to the Pick-Up by the chassis and the engine ground lead.
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
Once the lack of power to the spark plug has been
detected and the led indicates it can be ignited,
follow this procedure:
- Pick-Up check.
Disconnect the control unit connector and check
that the cable between terminal No. 3 (Green) and
terminal No. 12 (Black) is not interrupted.
The check includes the Pick-Up and its power line.
If a break in the circuit is found, check again the
flywheel and the engine earth connectors. If nonconforming values are measured, replace the
Pick-Up; otherwise, repair the cable harness.
Electric characteristic
ELE SYS - 61
Electrical system
LXV 125
Pick-up resistance value
Pick-up resistance value: 105 ÷ 124 Ohm
- HV primary coil check
Disconnect the control unit connector and check
that the cable between terminal No. 4 (violet) and
terminal No. 12 (black) is not interrupted (see figure).
If non-conforming values are measured, check
again the HV primary coil directly on the positive
and negative terminals.
If the values are correct, repair the cable harness
or reset the connections; otherwise, replace the
HV coil
Electric characteristic
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4 ÷
0.5 Ohm
- HV coil secondary check
Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see figure).
If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,
check the peak voltage with the multimeter adaptor.
Specific tooling
020409Y Multimeter adaptor - Peak voltage detection
Electric characteristic
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm
ELE SYS - 62
LXV 125
Electrical system
- Pick-Up
Disconnect the control unit connector and connect
the positive terminal to connector No. 3 and the
negative terminal to connector No. 12 (see figure).
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
Replace Pick-Up if non-conforming values are
measured.
N.B.
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Electric characteristic
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- H.V. coil
With the control unit and HV coil connected to the
circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor
and connect the positive terminal to the earth one
and the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS
BLACK.
Electric characteristic
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
Battery recharge circuit
The recharge system is provided with a three phase alternator with permanent flywheel.
The alternator is directly connected to the voltage regulator.
In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety
fuse.
This system therefore requires no connection to the key switch.
The three- phase generator provides good recharge power and at low revs a good compromise is
achieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Specific tooling
020333Y Single battery charger
ELE SYS - 63
Electrical system
LXV 125
020334Y Multiple battery charger
Stator check
- With a tester, check the circuit between connections 5-3 and 5-1 is not interrupted.
- Check the earth isolation on the three phases of
stators 5-earth, 3-earth, 1-earth.
Stage indicative resistance: 0.7 - 0.9 Ω
Minimum oil pressure switch check
- With a tester, check the circuit between connections 4 and ground (with engine off) is not interrupted.
Pick-Up check
- Check that there is a resistance of about 105 ÷
124 Ω at 20° C between connection 2 and ground.
- In case of values different from the ones stated,
replace the defective parts.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE
STATED.
Voltage regulator check
With a perfectly charged battery and lights off,
measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
Recharge system voltage check
Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery
voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V. Start
the engine and measure the current generated by the system with lights on and a high running engine.
ELE SYS - 64
LXV 125
Electrical system
In case the generated current value is lower than 10A, repeat the test using a new regulator and/stator
alternatively.
Choke Inspection
With the connector connected to the system,
check if there is voltage in both battery terminals
while the engine is running.
If voltage is detected, replace the automatic starter
as it is surely failing.
If no voltage is detected, connect the multimeter
negative terminal to the earth terminal and the
positive terminal to the automatic starter orange
cable; with the key switch set to «ON» and the engine emergency cut-off switch set to RUN, check
there is voltage in the battery; If there is no voltage,
check the wiring connections to the key switch and
that fuse No.1 works properly.
If there is voltage, check again the ignition control
unit connector. After disconnecting the starter,
start up the engine and keep it at idle speed and
check there is voltage when the multimeter positive terminal is connected to terminal No. 8 (Red/
Blue) and the negative one to terminal No. 11
(White/Red).
Replace the control unit if there is no voltage; otherwise, check the wiring connections between the
starter and the control unit.
ELE SYS - 65
Electrical system
Turn signals system check
- If the turn indicators do not work, proceed as follows:
- Disconnect the control unit connector and check
that there is voltage between terminal No. 9 (Blue)
and terminal No. 12 (Black) and the earth connection with the key switch set to "ON".
- Check that the same happens between terminal
No. 8 (Red/Blue) and terminal No. 12 (Black) and
earth connection.
If no voltage is detected, check the cable harness
and the connections; otherwise, proceed as follows:
- Jump terminals No.2 (Black/Blue) and No.9 (Sky
blue), see figure, and turn the turn indicator switch
alternatively to the left and the right with the key
switch in "ON" and check that the lights turn on.
If they do, replace the control unit because it is
faulty.
If they do not turn on, check the control unit-turn
indicator switch connection cable harness; then,
repeat the test.
ELE SYS - 66
LXV 125
LXV 125
Electrical system
Fuses
L'impianto elettrico è protetto da due fusibili da
15A «B» collocati accanto alla batteria e da due
fusibili da 7,5A «A» collocati sotto la calandra anteriore. Per rimuovere la calandra anteriore è necessario togliere, con l'ausilio di un cacciavite, la
placchetta con il logo Piaggio posto sullo scudo
anteriore quindi rimuovere la vite sottostante
CAUTION
IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH
IN ORDER TO AVOID DANGEROUS LEAKAGE OF BATTERY ELECTROLYTE.
CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT
ATTENTION TO THE TECHNICAL SPECIFICATIONS OF
THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING
AND RISK OF FIRE.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE
THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).
BULBS
1
Specification
High/low beam light bulb
2
Front tail light bulb
3
Front turn indicator bulb
4
Rear turn indicator light bulb
5
Stop and tail light bulb
6
12V - 2W warning light bulbs
Desc./Quantity
Type: Halogen (H4)
Power: 12V - 55/60W
Quantity: 1
Type: All glass
Power: 12V 5W
Quantity: 1
Type: Spherical
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
Type: Spherical
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
Type: Spherical
Power: 12V 21/5W
Quantity: 1
Type: All glass
Function: Turn indicators, engine oil, fuel reserve, highbeam light
Quantity:4
ELE SYS - 67
LXV 125
Electrical system
7
Specification
Instrument panel light bulbs
8
License plate light bulb
Desc./Quantity
Type: All glass
Power: 12V 1.2W
Quantity: 4
Type: ALL GLASS
Power: 12V - 5W
Quantity: 1
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance 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
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
Dry-charge battery
WARNING
- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact
with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about
15 minutes and seek immediate medical attention.
In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention
Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area
when recharging the battery indoors.
Always protect your eyes when working close to batteries.
Keep out of the reach of children.
ELE SYS - 68
LXV 125
Electrical system
Commissioning dry-charged batteries :
1) - Remove the short closed tube and the caps,
then pour sulphuric acid into the cells using the
type specified for batteries with a specific gravity
of 1.26, corresponding to 30 Be at a minimum temperature of 15°C until the upper level is reached.
2) - Leave to rest for at least 2 hours; then, restore
the level with sulphuric acid.
3) - Within the following 24 hours, recharge using
the specific battery charger (single) or (multiple) at
a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that
these values are stabilised.
4) - Once the charge is over, level the acid (by
adding distilled water). Close and clean carefully.
5) Once the above operations have been performed, install the battery on the vehicle ensuring
that it is wired up properly.
1 Hold the vertical tube
2 Look at the level
3 The float must be freed
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE
(WITH CLOSED END) NEAR THE + POSITIVE TERMINAL
WITH THE CORRESPONDING LONG TUBE (WITH OPEN
END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE
PROPERLY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Battery maintenance
The battery is an electrical device which requires careful monitoring and careful maintenance. The
maintenance rules are:
1) Electrolyte level check
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level. If it is necessary to add water too frequently, check the vehicle electrical
system: the battery works overcharged and is subject to quick wear.
2)Load status check
ELE SYS - 69
Electrical system
LXV 125
After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Battery cleaning
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS
AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT
IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
ELE SYS - 70
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
Exhaust assy. Removal
- Remove the 2 fixing nuts from the manifold to the
head
- Unscrew the 2 screws fixing the muffler to the
housing; then remove the whole muffler paying attention to the interference between its supporting
bracket and the cooling cover.
Removal of the engine from the vehicle
- Remove the left and right side fairings
- Remove the helmet compartment
Remove the full muffler assembly.
- Remove the 3 rear brake transmission fixing
screws indicated in the photograph
- Disconnect the rear brake transmission unscrewing the set screw
- Disconnect the belt cooling tube and the swinging
arm retaining spring shown in the photograph
- Disconnect the spark plug tube
ENG VE - 72
LXV 125
LXV 125
Engine from vehicle
- Remove the throttle control cable from the carburettor, indicated in the photograph
- Remove the fuel supply pipe from the carburettor
- Remove the fuel valve low-pressure pipe from the
manifold as shown in the photograph
- Remove the flywheel wiring connector, the earth
terminal and the starter motor positive cable indicated in the figure
ENG VE - 73
Engine from vehicle
- Remove the protection sheath indicated in the
figure and disconnect the automatic starter, carburettor heater and TPS connectors
- Unscrew the engine pin-swinging arm nut on the
right-hand side of the vehicle and slide off the pin
on the left hand side
- Support the vehicle adequately (with a jack) and
remove the shock absorber lower clamping. The
engine is now free.
ENG VE - 74
LXV 125
INDEX OF TOPICS
ENGINE
ENG
Engine
LXV 125
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary
to remove the rear plastic cover first by inserting a
screwdriver in the corresponding slotted holes.
Using the clutch bell lock wrench, remove the driven pulley axle locking nut and recover the washer.
- Remove the cap/dipstick from the engine oil filling
hole.
- Remove the 10 screws and the earth cable fastened under one of them.
- Remove the transmission cover. If this operation
is performed directly on the vehicle, it is necessary
to remove the cooling air coupling and the three air
filter housing retainers.
Specific tooling
020423Y driven pulley lock wrench
Kickstart
- Check the following for wear: toothed section,
toothed section shaft, cover seat bushing, pinion
shaft and its seating in the crankcase and the return spring.
- Remove the damaged components.
- Lubricate the spring with the recommended
grease.
- Remove the toothed sector and load the spring
with an appropriate tool.
- Refit the washer, the seeger ring and the Kickstart lever.
Specific tooling
020432Y Tool to fit the start-up sector spring
Recommended products
ENG - 76
LXV 125
Engine
AGIP GREASE MU3 Grease for odometer
transmission gear case
Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
- Operating the starter lever, load the spring and
introduce the pinion in its seat.
- Refit the intake throat with the 3 screws and the
Kick-starter cover with the 4 screws. Tighten the
screws to the prescribed torque.
- Remove the start-up pinion pushing the starter
lever.
- Unscrew the kick starter screw, remove the lever.
-Remove the seeger ring and the washer indicated
in the figure.
-Pull out the toothed section.
WARNING
THE SECTION KEEPS THE SPRING SET, BE CAREFUL SO
AS NOT TO CAUSE ANY ACCIDENTS
Air duct
- Unscrew the Torx screws fixing the air manifold
bulkhead and remove the bulkhead.
- Remove the 3 screws, then take out the manifold
as well as the filter.
ENG - 77
Engine
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.
- Use the specific tools to remove the bearing from
the crankcase.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
Refitting the driven pulley shaft bearing
- Heat up the crankcase inside with the hot air gun.
- Insert the bearing in its housing, refit the Seeger
ring.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020151Y Air heater
020376Y Adaptor handle
ENG - 78
LXV 125
LXV 125
Engine
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
Removing the driven pulley
- Remove the spacer, the clutch bell and the whole
driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
Checking the bell working surface eccentricity
- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to
check the crankshaft alignment.
ENG - 79
Engine
LXV 125
- Using a feeler pin 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 support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Removing the clutch
- Prepare the locking tool for the driven pulley with
the pins half-screwed in the tool set to «C».
- Fit the driven pulley unit in the tool so as the bolt
get into the masses clutch support holes. Afterwards make the support screw make contact with
a minimum force.
- Using the specific wrench, inserted 46 mm from
the side, remove the clutch central locking nut.
- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE
TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE
SPECIFIC TOOL.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
020444Y009 46x55 Wrench
ENG - 80
LXV 125
Engine
Inspecting the clutch
- Check the thickness of the clutch mass friction
material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
- Remove the 3 guide pins and the movable halfpulley.
Removing the driven half-pulley bearing
- Remove the retaining ring using two flat blade
screwdrivers.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Remove the roller bearing using the specific extractor.
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
ENG - 81
Engine
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide
Inspecting the driven fixed half-pulley
- Measure the external diameter of the pulley bushing.
Characteristic
Minimum diameter permitted
Ø 40.96 mm
Standard diameter
Ø 40.965 mm
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two Orings.
- Measure the inside diameter of the mobile halfpulley bushing.
Characteristic
Minimum admissible diameter
Ø 41.08 mm
Standard diameter
Ø 41.035 mm
ENG - 82
LXV 125
LXV 125
Engine
Refitting the driven half-pulley bearing
- Assemble a new roller case using the specific
punch, fit the bearing with the label facing outward
and insert it completely up to the punch on the halfpulley.
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
- To assemble the new ball bearing insert it completely down in its housing with the specific punch
and finally assemble the Seeger ring.
Specific tooling
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide
Refitting the driven pulley
- Check that the faying surfaces between the 2
half-pulleys and the belt do not show any signs of
wear, scoring and grease.
- Insert the new oil seals and O-rings on the movable half-pulley.
- Assemble the half-pulley on the ringlet with the
appropriate protection sheath.
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the
driven pulley unit with around 6 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 presence of grease beyond the O-rings.
Specific tooling
ENG - 83
Engine
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
Inspecting the clutch spring
- Measure the unloaded length of the spring of the
movable driven half-pulley.
Characteristic
Standard length:
106 mm
Refitting the clutch
- Check the thickness of the clutch mass friction
material.
-The masses must not show traces of lubricants;
otherwise, check the driven pulley unit.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN
CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS SO AS TO
PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted:
1 mm
ENG - 84
LXV 125
LXV 125
Engine
- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring 11 with the chamfering
facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the driving belt into the pulley unit according to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
- Loosen the tool clamp and insert the belt according to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.
Specific tooling
ENG - 85
LXV 125
Engine
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 46x55 Wrench
Locking torques (N*m)
Nut locking clutch unit on pulley 55 ÷ 60 Nm
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
Drive-belt
During the wear checks foreseen in the scheduled
maintenance services at 6,000 km; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
- Check that the driving belt is not damaged.
- Check the width of the belt.
BELT SIZE
Specification
Minimum width
Standard width
ENG - 86
Desc./Quantity
21.5 mm
22.5 ± 0.2 mm
LXV 125
Engine
Removing the driving pulley
- Lock the driving pulley with the specific tool as
shown in the figure. - Disassemble the central nut
and the Belleville washer, remove the drive and
the 2 washers. - Remove the stationary half pulley
and the steel washer.
Specific tooling
020368Y driving pulley lock wrench
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide pads.
Inspecting the rollers case
- Check that the internal bushing is not abnormally worn and measure inner diameter.
N.B.
DO NOT LUBRICATE OR CLEAN THE BUSHING.
BUSHING ROLLER CONTAINER
Specification
Maximum allowable diameter
Standard diameter
Desc./Quantity
Ø 26.121 mm
Ø 26+0 +0.021 mm
BUSH SLIDE PULLEY
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 25.950 mm
Ø 26-0.020 -0.041 mm
VARIABLE SPEED ROLLERS
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 18.5 mm
Ø 26±0.1 mm
ENG - 87
Engine
- Check the guide shoes for the variator back-plate
are not worn.
- Check there is no wear in the roller housing, and
the surfaces in contact with the belt on either of the
pulley halves.
Refitting the driving pulley
- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread threadlock on the thread and screw the nut
to the prescribed torque.
-Avoid the half-pulley rotation using a calliper
spanner
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
Specific tooling
020368Y driving pulley lock wrench
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Locking torque 75 ÷ 83
ENG - 88
LXV 125
LXV 125
Engine
Refitting the transmission cover
- Check the presence of the 2 centring dowels and
the correct installation of the sealing gasket for the
oil sump on the transmission cover.
- Replace the cover tightening the 10 screws at the
specified torque.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling
020423Y driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage tap
located inside the hub cover
- Remove the brake shoe and relevant spring
- Remove the 7 flanged screws as shown in the
figure.
- Remove the rubber cover and the brake pad lever
sliding unscrewing the relevant retaining screw to
reach the rear of the cover
- Take off the hub cover and relevant gaskets
ENG - 89
Engine
Removing the wheel axle
Remove the intermediate gear and the complete
hub cover.
Removing the hub bearings
- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are detected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y009 Driver for OD 42-mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Remove the bearing with the adequate tools adequately supporting the hub cover, as shown in the
figure.
Specific tooling
020376Y Adaptor handle
020364Y 25-mm guide
ENG - 90
LXV 125
LXV 125
Engine
With the appropriate tools, remove the oil seal as
shown in the figure.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
Removing the driven pulley shaft bearing
If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven
pulley.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.
- Remove the seeger ring shown in the figure
With the sectional punch, remove the driven pulley
shaft bearing.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide
See also
Removing the driven pulley
Inspecting the hub shaft
- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged components.
ENG - 91
Engine
LXV 125
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the
brake camshaft. - If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Heat up the parts using the specific heat gun
Specific tooling
020150Y Air heater support
020151Y Air heater
- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
- Refit the Seeger ring with the opening facing the
bearing as shown in the figure and fit a new oil
guard flush with the crankcase.
Refitting the wheel axle bearing
- Heat up the parts using the specific heat gun
Specific tooling
020151Y Air heater
020150Y Air heater support
-The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide
020360Y Adaptor 52 x 55 mm
020376Y Adaptor handle
ENG - 92
LXV 125
Engine
•
Assemble the Seeger ring.
•
Assemble the oil seal flush with the internal surface as shown in the figure to
the hub using the adequate tools and
with the seal lip towards the inside of
the hub.
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
Refitting the hub cover bearings
- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the
specific heat gun.
Specific tooling
020150Y Air heater support
020151Y Air heater
- The three 15 mm bearings must be fitted using
the appropriate tools.
Refitting the hub bearings
- Insert the cover prepared in the crankcase taking
care of inserting the gear of the pulley shaft on the
intermediary gear.
ENG - 93
Engine
LXV 125
Refitting the ub cover
- Fit a new gasket together with the centring dowels.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Screw the 7 screws to the specified torque, positioning the support plate of the pipe in the position shown in the figure.
Locking torques (N*m)
Locking torque 24 ÷ 27
Flywheel cover
Cooling hood
-Remove the housing acting on the 4 retaining
screws.
CAUTION
DURING REMOVAL SLIDE THE HOUSING CONNECTOR
ON THE HOUSING.
- Loosen the clamp and remove the carburettor
from the manifold.
-Remove the complete manifold acting on the 2
retainers as shown in the figure.
- Remove the 2 self threading screws, left and right
and the lateral base retaining screw on the crankcase base.
- Take off the housings.
- Remove the gasket seal of the housing on the
head.
N.B.
IF THE FLYWHEEL HOUSING IS NOT REMOVED, IT IS ALSO NECESSARY TO REMOVE THE TWO KNOB SCREWS.
On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest
to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.4 mm to 1.5
ENG - 94
LXV 125
Engine
mm. Remember that such operation must have performed on a disassembled manifold which must be
cleaned afterwards.
Cooling fan
- Refit the parts in reverse order of the removal
operation.
- Make sure that there are spacers with the two
rear retainers of the housing.
- The long spacers should be in a high position.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR.
- Remove the cooling fan by acting on the three
fixings indicated in the figure.
Removing the stator
- Remove the electric terminal of the minimum oil
pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
ENG - 95
Engine
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
- Place the cable harness as shown in the figure.
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE PIN AS
SHOWN IN THE DETAIL DRAWING.
Locking torques (N*m)
Stator screw 3 ÷ 4
Flywheel and starting
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper
spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
Specific tooling
020565Y Flywheel lock calliper spanner
- Extract the flywheel with the extractor.
Specific tooling
008564Y Flywheel extractor
ENG - 96
LXV 125
LXV 125
Engine
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key
properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
N.B.
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED
Locking torques (N*m)
Flywheel nut 52 ÷ 58
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.
- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.
Locking torques (N*m)
Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
ENG - 97
Engine
Removing the timing system drive
- Remove the parts listed below first: transmission
cover, belt driving pulley, oil pump pulley cover and
pinion separator washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve
lifter assembly and the automatic valve lifter assembly and its end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft command pulley and its
washer.
- Remove the command sprocket wheel and the
timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner pad.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
See also
Transmission cover
Removal
Removing the driving pulley
ENG - 98
LXV 125
LXV 125
Engine
Removing the cam shaft
- Remove the two screws and the cam shaft retainer shown in the diagram.
- Remove the cam shaft.
- Remove the pin of the rocking levers from the
flywheel side holes.
- Remove the rocking levers and the elastic washer.
N.B.
MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO
AS TO AVOID THE INVERSION OF INLET WITH THE OUTLET.
Removing the cylinder head
- Remove the spark plug.
- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two centring dowels and
the gasket.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
ENG - 99
Engine
Removing the valves
- Using the specific tool fitted with the element
shown in the figure, remove the cotters, the plates
and the spring between the valves.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
- Remove the oil seals with the appropriate tool.
- Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
Removing the cylinder - piston assy.
- Remove the chain guide pad.
- Remove the cylinder base gasket.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE
REMOVING THE CYLINDER.
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the 3 piston rings from the piston.
N.B.
BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
ENG - 100
LXV 125
LXV 125
Engine
Inspecting the small end
- Measure the internal diameter of the small end
using an internal micrometer.
N.B.
IF THE DIAMETER OF THE ROD SMALL END EXCEEDS
THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF
WEAR OR OVERHEATING REPLACE THE CRANKSHAFT
AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".
Characteristic
Rod small end check-up: Maximum diameter
15.030 mm
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
Inspecting the wrist pin
- Check the outer diameter of the gudgeon pin.
Characteristic
Standard pin diameter
14.996 ÷ 15 mm
Minimum diameter permitted
Ø 14.994 mm
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
Characteristic
Piston pin bore - standard diameter
Ø 15+0.001 +0.006
ENG - 101
Engine
LXV 125
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Measure 36.5 mm from the piston crown's shown
in the figure.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
- 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).
Characteristic
Maximum allowable run-out:
0.05 mm
- The cylinder rectifying operation should be carried out with a surfacing that respects the original
angle.
- The cylinder surface roughness should be 0.9
micron.
- This is indispensable for a good seating of the
sealing rings, which in turn minimises oil consumption and guarantees optimum performance.
- The pistons are oversized due to cylinder rectification and are subdivided into three categories
1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They
are also classified into 4 categories A-A, B-B, CC, D-D.
Inspecting the piston
- Carefully clean the seal housings.
- Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as
shown in the diagram.
- If the clearance is greater than that indicated in the table, replace the piston.
ENG - 102
LXV 125
Engine
STANDARD COUPLING CLEARANCE
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
0.025 ÷ 0.070
0.015 ÷ 0.060
0.015 ÷ 0.060
Initials
Quantity
MAXIMUM ADMITTED CLEARANCE AFTER USE
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
0.080 mm
0.070 mm
0.070 mm
Initials
Quantity
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
- Fit the pin stop ring onto the appropriate tool.
Specific tooling
020430Y Pin lock fitting tool
- With the opening in position indicated on the tool,
take stop ring in the closed position using the
punch.
- Fit the wrist pin stop using the plug as shown in
the figure
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE
USED MANUALLY.
CAUTION
USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
ENG - 103
Engine
Refitting the piston rings
- Place the oil scraper spring on the piston.
- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the crown of the piston.
The tapered side of the middle piston ring should
always be facing away from the crown of the piston.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'top' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
N.B.
SO AS TO OBTAIN THE BEST CONFIGURATION THE 2
SEALING RINGS ARE MADE WITH A CONTACT CONICAL
CYLINDER SECTION.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness
determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.
Specific tooling
020426Y Piston fitting fork
ENG - 104
LXV 125
LXV 125
Engine
020427Y Piston fitting band
Inspecting the cylinder head
- Using a trued bar check that the cylinder head
surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
Maximum admitted unevenness: Head check
0.05 mm
STANDARD DIAMETER
Specification
Standard diameter
Standard diameter
Standard diameter
Desc./Quantity
A Ø 32.5 ÷ 32.525
B Ø 20 ÷ 20.021
C Ø 12 ÷ 12.018
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft drive pulley, the chain
assembly and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts. if the
chain, pinion or pulley are worn, replace the whole
assembly.
ENG - 105
LXV 125
Engine
- Remove the central screw 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
assembly.
Inspecting the valve sealings
- Measure the width of the sealing surface on the valve seats.
VALVE SEAL SURFACE
Specification
Inlet valve - seal surface
Outlet valve - seal surface
Desc./Quantity
2.4 ÷ 2.8 mm
2.2 ÷ 2.6 mm
Inspecting the valve housings
- Remove any carbon formation from the valve guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights in the rocker arm push direction.
Characteristic
Standard drainage guide diameter
5.012 mm
Standard inlet guide diameter
5.012 mm
ENG - 106
LXV 125
Engine
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the specified limits, replace the cylinder head.
- Check width of the impression on the valve seat
«V»
Characteristic
Wear limits:
Max. 1.6 mm.
Inspecting the valves
- Measure the diameter of the valve stems in the
three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
Characteristic
Minimum diameter admitted - Inlet:
4.96 mm
Minimum diameter admitted - Outlet:
4.95 mm
Standard clearance - Inlet:
0.013 ÷ 0.040 mm
Standard clearance - Outlet:
0.025 ÷ 0.052 mm
Maximum clearance admitted- Inlet:
0.062 mm
Maximum clearance admitted - Outlet:
0.072 mm
- Check that there are no signs of wear on the
contact surface with the articulated register terminal.
- If the sealing surface on the valves is wider than
the specified limit, damaged in one or more points
or curved, replace the valve with a new one.
Characteristic
Standard valve length - Inlet:
80.6 mm
Valve standard length: drainage
ENG - 107
Engine
79.6 mm
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During
grinding, keep the cylinder head in a horizontal
position. This will prevent the lapping compound
residues from penetrating between the valve stem/
guide coupling.
CAUTION
TO AVOID SCORING THE CONTACT SURFACE, DO NOT
KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER
HEAD AND THE VALVES WITH A SUITABLE PRODUCT
FOR THE TYPE OF LAPPING COMPOUND BEING USED.
- Insert the valves into the cylinder head.
- Test the 2 valves alternatively.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter
halves show no signs of abnormal wear.
- Check the length clearance of the springs.
Characteristic
Valve spring length
33.9 ÷ 34.4 mm
ENG - 108
LXV 125
LXV 125
Engine
Refitting the valves
- Lubricate the valve guides with engine oil.
- Place the lower plates of the valve spring on the
head.
- Use the punch to fit the 2 sealing rings one at a
time.
Specific tooling
020306Y Punch for assembling valve seal
rings
- Fit the valves, the springs and the spring retaining
caps. Using the appropriate tool with adapter 11,
compress the springs and insert the cotters in their
seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear
on the cams.
Characteristic
Standard diameter Bearing A
Ø: 32.5 mm -0.025 -0.050 mm
Standard diameter Bearing B
20 -0.020 -0.041 mm
Minimum admitted diameter bearing A
Ø: 32.440 mm
Minimum admitted diameter bearing B
Ø: 19.950 mm
Inlet cam height
27.512 mm
Outlet cam height
27.212 mm
ENG - 109
Engine
LXV 125
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
Characteristic
Maximum axial clearance admitted
0.42 mm
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check there are no signs of scoring or wear on
the rocking lever bolt.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
- Measure the internal diameter of each rocking
lever.
-Check that the elastic washer dedicated to the
axle clearance of the rocking levers is not worn. In case of anomalies, replace the damaged components.
Characteristic
Minimum diameter permitted
Ø 11.970 mm
Maximum diameter admitted
Ø 12.030 mm
Refitting the head and timing system components
- Fit the timing chain guide pad.
- Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder.
ENG - 110
LXV 125
Engine
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
Locking torques (N*m)
Locking torque 28 ÷ 30
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the tensioner pad by the cylinder head.
- Fit the spacer and the screw fastener.
- Fit the pin, the outlet rocking lever, the spring
washer and the inlet rocking lever.
- Lubricate the 2 rocking levers through the holes
at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams opposing the
rocking levers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
ENG - 111
Engine
LXV 125
- Refit the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head.
- Fit the pulley onto the camshaft.
- Assemble the counterweight with the corresponding fixing screw and tighten to the specified
torque.
Locking torques (N*m)
Locking torque 7 ÷ 8.5
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
cam shaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
approximately 180°.
N.B.
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed torque.
Locking torques (N*m)
Locking torque 12 - 14
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed
torque.
ENG - 112
LXV 125
Engine
Locking torques (N*m)
Locking torque 11 ÷ 13
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed
torque.
Locking torques (N*m)
Locking torque 5 - 6
- Adjust the valve clearance.
- Fit the spark plug
Electric characteristic
Recommended spark plug:
CHAMPION RG4HC
Electrode gap
0.8 mm
Locking torques (N*m)
Locking torque 12 - 14
- Assemble the casing sealing gasket on the head.
On the fitting direction, use the supplements on the
timing side as reference.
- Assemble the screw fixing the housing to the
crankcase to the specified torque and the 2 selfthreading screws joining the half-shells.
- Take care that the gasket is well inserted in its
housing during the assembly stage.
- Place the spark plug access cap.
Locking torques (N*m)
Locking torque 3 ÷ 4
- Fit the inlet manifold and lock the 2 screws to the
specified torque.
- Fit the carburettor onto the inlet manifold and lock
the clamp
N.B.
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT
ON THE MANIFOLD.
Locking torques (N*m)
Locking torque 11 ÷ 13
ENG - 113
Engine
- Refit the cylinder head cover, tightening the 4
clamping screws to the prescribed torque.
- Refit the fan and the housing.
- Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as
described in the lubrication chapter.
- Reassemble the driving pulley, the belt and the
transmission cover as described in the transmission chapter.
Locking torques (N*m)
Locking torque 11 ÷ 13
Crankcase - crankshaft
- Precautionary remove the following units:
transmission cover, driving pulley, driven pulley
and belt, rear hub cover, gears, bearings and oil
seals as described in the transmission chapter.
- Remove the oil sump, the by-pass, the chain
compartment cover and the oil pump as in the lubrication chapter.
- Remove the flywheel cover, the fan, the flywheel
and the stator as described in the magneto flywheel chapter.
- Remove the oil filter and the oil pressure bulb.
- Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter.
- Remove the 2 retainers indicated in the figure
and the starter motor.
- Before opening the crankcase, it is advisable to
check the axial clearance of the crankshaft. To do
this, use a plate and a support with specific tool
dial gauge.
Specific tooling
020262Y Crankcase splitting strip
020335Y Magnetic support for dial gauge
Characteristic
Standard clearance
ENG - 114
LXV 125
LXV 125
Engine
0.15 ÷ 0.40 mm
Splitting the crankcase halves
Remove the 11 coupling screws to the crankcase.
- Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase.
Remove the crankshaft.
CAUTION
IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.
- Remove the coupling gasket of the crankcase
halves.
- Remove the two screws and the internal cover
shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance
0.20 ÷ 0.50 mm
ENG - 115
LXV 125
Engine
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
CAUTION
BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard clearance
0.036 ÷ 0.054 mm
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
Characteristic
Distance between the shoulders
55.67 ÷ 55.85 mm
- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces
shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
STANDARD DIAMETER
Specification
Category 1
Class 2
ENG - 116
Desc./Quantity
28.998 ÷ 29.004
28.004 ÷ 29.010
LXV 125
Engine
Inspecting the crankshaft alignment
To install the drive shaft on the support and to
measure the misalignment in the 4 points indicated
in figure.
- Check that the driving shaft cone, the tab seat,
the oil seal capacity, the toothed gear and the
threaded tangs are in good working order.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be replaced. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 117
Engine
Inspecting the crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean the all surfaces and oil
ducts.
- On the transmission side crankcase half, take
particular care cleaning the housing and oil ducts
for the following components: the oil pump, the oil
by-pass valve, the main bushings and the cooling
jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the flywheel side oil seal.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
- Inspect the mating surfaces on the crankcase
halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder
and the mating surfaces between the crankcase
halves.
- Defects in the crankcase coupling gasket or the
surfaces indicated in the figure can cause a drop
in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.
ENG - 118
LXV 125
LXV 125
Engine
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and dimensions.
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one containing holes and channels for
lubrication and the other solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposed 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 figure.
- The oil supply channel section is also affected by
the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THIS POSITION OF THE BUSHINGS ON THE
CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE
HALVES.
Characteristic
Standard driving depth
1.35 ÷ 1.6
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
ENG - 119
LXV 125
Engine
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
3 - The main bushings are subdivided into 3 thickness categories; see the table below:
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE
THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification
B
C
E
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two
screws to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
- Fit the oil filter joint and tighten it to the prescribed
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, together with the locating dowels.
Locking torques (N*m)
Locking torque 27 ÷ 33
ENG - 120
Desc./Quantity
Blue
Yellow
Green
LXV 125
Engine
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 11 screws and tighten them to the prescribed torque.
N.B.
WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Lubricate the flywheel oil seal.
- Use the appropriate tool to assemble the oil seal.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the pre-filter on the engine with its corresponding cover to the specific torque.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE
BETTER SEALING PERFORMANCE.
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Locking torques (N*m)
Locking torque 24 ÷ 30
Lubrication
ENG - 121
Engine
Conceptual diagrams
ENG - 122
LXV 125
LXV 125
Engine
Oil pressure check
- After removing the cover protections as described in the "Flywheel" chapter, disconnect the electrical connexion of the minimum oil pressure
switch and then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 ÷ 4.2 atm.
- Remove the appropriate tools once the measurement is complete, refit the oil pressure switch
and washer, tightening it to the prescribed torque
and fit the fan cover.
- If the oil pressure is outside 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 GOOD
CONDITION.
Characteristic
Minimum pressure admitted
3.2 atm.
Locking torques (N*m)
Locking torque 12 ÷ 14 (also valid for the control connector).
Crankshaft oil seals
ENG - 123
Engine
Removal
- First remove the transmission cover and the complete driving pulley
- Install the base of the appropriate tool on the oil
guard using the screws provided.
- Screw the threaded bar onto the base of the tool
and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Prepare the new oil guard, lubricating the sealing
lip. Warning: do not lubricate the surface for keying
onto the engine crankcase.
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO
THE ENGINE CRANKCASE.
ENG - 124
LXV 125
LXV 125
Engine
- Preassemble the oil seal with the appropriate
tool, positioning the screws
- Place the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
SHEATH.
- Orientate the oil guard by inserting the bracket
which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
ENG - 125
Engine
LXV 125
- Use the nut to move the base of the tool until you
can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
Assemble a new oil seal on the flywheel side using
the specific tool as shown in the photograph
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Oil pump
Removal
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
using a screwdriver inserted through one of its two
holes.
ENG - 126
LXV 125
Engine
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the pulley.
- Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as
shown in the figure.
- Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.
- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the
clip.
- Using a thickness gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted
0.12 mm
ENG - 127
Engine
Measure the distance between the outer rotor and
the pump body; see figure.
Characteristic
Admissible limit clearance:
0.20 mm
Check the axial clearance of the rotors with a trued
bar as reference, as shown in the figure.
Characteristic
Limit values admitted:
0.09 mm
Refitting
- Check there are no signs of wear on the oil pump
shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the assembly.
- Fit the pulley to the pump, the central screw to
the specified torque and the belleville washer.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER
(CURVED) RIM TOUCHES THE PULLEY.
Locking torques (N*m)
Central screw 12 ÷ 14 Nm Cover screws 0.7 ÷ 0.9 Nm
ENG - 128
LXV 125
LXV 125
Engine
Removing the oil sump
- Remove the oil filler plug, the transmission cover,
the complete drive pulley assembly with belt and
the sprocket wheel, as described in the Transmission chapter.
- Drain the oil from the sump as described above.
- Remove the 7 screws indicated in the figure and
the 2 rear brake transmission fixing brackets.
- Remove the spring, the by-pass piston and the
gasket shown in the second image.
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 defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 129
Engine
Refitting the oil sump
- Refit the by-pass valve plunger in its housing.
- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake transmission support brackets and the screws in the reverse order from which
they were removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as described in the "Transmissions" chapter.
- When testing the lubrication system, refer to
the "Crankcase and Crankshaft" chapter, regarding lubrication of the crankshaft and connecting rod
Locking torques (N*m)
Locking torque 11 ÷ 13
SAS valve
Inspecting the one-way valve
- Remove the SAS valve.
- Provisionally assemble the rubber coupling of the
SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rubber coupling as shown in the photograph.
- Set the pump to the low-pressure position (VACUUM).
- Operate the pump slowly.
- Check that the one way valve allows the air to
pass through causing a slight vibration.
- Switch the pump to pressure mode (PRESSURE).
ENG - 130
LXV 125
LXV 125
Engine
- Operate the pump slowly and check if there is an
increase of pressure. A small leakage is considered to be normal.
If anomalies are detected, replace the pump.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN
RUBBER COUPLING AND FILTER OVERHEATING
N.B.
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING
Specific tooling
020329Y MityVac vacuum-operated pump
Inspecting the cut-off
- Remove the SAS valve.
- Connect the MITYVAC pump in low-pressure
mode (VACUUM) to the CUT-OFF valve vacuum
intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept all the time.
- If a worn seal is detected, replace it.
- With a "T" bypass and flexible rubber hoses make
a parallel connection between the rubber coupling
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump set to the low-pressure mode
(VACUUM).
- Using a pair of long flat pliers, choke the rubber
hose next to the valve.
- Operate the pump until vacuum is higher than 0.5
BAR.
- Release the hose and check how the vacuum reacts. - Under normal functioning conditions the
vacuum undergoes a slight fall and then readjusts.
There follows a slow and continuous loss of depression up to approximately 0.4 BAR. At this point
the valve opens and the depression is suddenly
set to zero.
ENG - 131
Engine
Lack of tightness or the fact that the valve opens
at different vacuum values should be regarded as
anomalies. In this case, replace it.
N.B.
LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS
IN EXHAUST NOISE (EXPLOSIONS IN THE MUFFLER). INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT
IN CATALYTIC CONVERTER MALFUNCTIONING
N.B.
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES
JEOPARDISING THE CORRECT OPERATION OF THE
CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
020329Y MityVac vacuum-operated pump
Fuel supply
- Disconnect the fuel supply and the suction taking
pipe from the carburettor.
- Check that there are no fuel leaks between the
two tubes.
- Close the fuel outlet pipe.
- By means of the MITIVAC pump apply 0.1 bar of
suction to the tap.
- Make sure that the suction is kept stable and that
and that there are no fuel leaks.
- Reconnect the suction pipe to the manifold.
- Position the fuel pipe with the outlet at the point
of the tap.
- Turn the engine by using the starter for five seconds with the carburettor at minimum.
- Take up the fuel by means of a graded burette.
N.B.
THE MEASUREMENT MAY BE FALSIFIED BY THE INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION
OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-
ENG - 132
LXV 125
LXV 125
Engine
LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY
REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.
Specific tooling
020329Y MityVac vacuum-operated pump
Characteristic
Minimum flow rate
20 cc
- Completely empty the gas tank.
- Remove the petrol delivery tube and the suction
tube.
- Loosen the clip and remove the tap.
- Clean the tank and the filter of the tap with a specific solvent.
- Refit the tap making sure that there is an O-Ring.
- Turn the tap to the direction it had before it was
removed and block the clip.
N.B.
THE FILTER CAN BE UNSCREWED FROM THE COCK TO
FACILITATE CLEANING.
Removing the carburettor
- To detach the carburettor from the engine, it is
necessary to move the air filter and remove the
throttle control transmission, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, the heater, the
intake fitting and the TPS cable.
- Remove the heater
ENG - 133
Engine
- Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with
the gasket.
- Remove the 4 fixing screws shown in the figure
and the vacuum chamber cover.
WARNING
DURING THE REMOVAL OF THE CARBURETTOR COVER
TAKE SPECIAL CARE NOT TO RELEASE THE SPRING
ACCIDENTALLY.
ENG - 134
LXV 125
LXV 125
Engine
- Remove the vacuum valve together with the diaphragm.
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
- Remove the 4 screws indicated in the figure.
- Remove the chamber with the accelerating
pump, its control and gasket.
ENG - 135
Engine
- Remove the oil pump seal.
- Remove the intake and outlet valves of the intake
pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP VALVES ARE
MADE UP OF NOZZLES, SPRING AND BALL.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP AND ITS
CONTROL.
Adequately support the carburettor and using a
rod and hammer remove the float pin acting from
the throttle control side.
- Remove the float and the plunger.
- Remove the maximum nozzle
-Remove the maximum nozzle.
ENG - 136
LXV 125
LXV 125
Engine
-Remove diffuser.
- Remove the sprayer.
N.B.
WHEN CLEANING THE CARBURETTOR BODY REMOVE
THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO
REMOVE IT AS THIS WILL ONLY DAMAGE IT.
ENG - 137
Engine
-Remove the minimum nozzle.
- Remove the minimum flow set screw and the
spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR
PROGRESSIONS AND INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES THE
SHAFT.
Refitting the carburettor
- Before refitting, wash the carburettor body accurately with petrol and compressed air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
ENG - 138
LXV 125
LXV 125
Engine
- For maximum circuit, check the air adjustment is
correct as shown in the figure.
- For the minimum circuit, make sure the following
points are properly cleaned: air gauging, outlet
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the
nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
- Check that the coupling surfaces, the tank and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
ENG - 139
Engine
LXV 125
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the
sprayer maximum circuit, the diffuser and the nozzle.
- Introduce the sprayer in the carburettor body with
the shortest cylindrical part directed to the diffuser.
- Assemble the diffuser making sure the sprayer is
being adequately inserted and lock it.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock absorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
- Introduce the float with the rod on the fuel feeding tube side.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
ENG - 140
LXV 125
Engine
- Remove the drainage screw from the tank, wash
and blow it properly and make sure the acceleration pump pipes are clean.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves following this order:
INTAKE VALVE (A)
•
Spring
•
Ball
•
Nozzle
IN VALVE (M)
•
Ball
•
Spring
•
Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING TO THE ACCELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small
amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fastening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
N.B.
MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED
N.B.
AVOID DEFORMING THE ACCELERATION PUMP CONTROL ROCKING LEVER.
- Wash and blow the flow screw properly.
- Check that screw is not deformed and/or rusty.
- Assemble the spring on the screw.
- Screw the flow screw on the carburettor body.
- The screw final position should be determined by an exhaust fume analysis.
- Adjust the carburettor by turning the screw twice from the close position.
ENG - 141
Engine
LXV 125
Level check
- Place the carburettor inclined as shown in the
figure.
- Check that the float reference is parallel to the tank coupling surface
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
Inspecting the valve and needle
- Check that the tapered pin of the vacuum valve
does not show wear.
- Check that the depression valve does not show
threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has
hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve
housing.
- Reassemble the vacuum valve on the carburettor
body taking care that the tapered pin is inserted
into the sprayer.
N.B.
THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE
POSITION.
ENG - 142
LXV 125
Engine
- Reassemble the spring with the pin lock.
- Remove the cover of the vacuum chamber being
careful to correctly insert the spring in its place on
the cover.
- Tighten the screws.
- Wash and blow dry the starter support.
Assemble a new gasket on the carburettor body
and tighten the 2 fixing screws.
Inspecting the automatic choke device
- Check that the automatic starter piston is not deformed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not deformed.
- The starter must be more or less functional depending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the ambient temperature.
- The starter should disconnect progressively by
means of electrical heating.
- Check the starter resistance when adjusted to the
ambient temperature.
ENG - 143
Engine
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possible.
- The correct warm up time depends on the ambient temperature.
- If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
plate with the machined side contacting the starter,
tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION
NOT TO GENERATE SHORT CIRCUITS USE A CABLE
SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE STARTER.
Characteristic
Check the automatic starter: Kehin: Protrusion
value
10 mm at about 20°C
Check the automatic starter: Keihin maximum
time
5 min
Starter resistance:
20 Ohm
ENG - 144
LXV 125
LXV 125
Engine
Adjusting the idle
- The engine does not require frequent idle speed
adjustments, but it is essential to strictly follow certain rules when adjusting the idle speed.
- Before adjusting the carburettor make sure to respect the lubrication requirements, valve clearance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 minutes at approximately 50 kph.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly prepared for probes.
- Start the engine and before adjusting the idle
speed, make sure that the oil temperature is between 70÷80 °C.
- Using the rpm indicator of the analyser or an independent one (020332y), adjust the idle set
screw until 1600 ÷ 1700 rpm is obtained.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED.
CORRECT COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000
ENG - 145
INDEX OF TOPICS
SUSPENSIONS
SUSP
LXV 125
Suspensions
Front suspension
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
- Remove the five Allen screws that fix the wheel
to the hub.
N.B.
BEFORE REMOVING THE WHEEL HUB, REMOVE THE
BRAKE CALLIPER.
Front wheel hub overhaul
- Remove the ball bearing check seeger ring indicated in the photograph
Extract the ball bearing using the specific tool
Specific tooling
001467Y014 Pliers to extract ø 15-mm bearings
001467Y017 Bell for bearings, OD 39 mm
SUSP - 147
Suspensions
- Remove the oil seal on the roller bearing side
using a screwdriver.
- Remove the roller bearing using the specific tool
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
- Heat the roller bearing seat with a heat gun
- Use the specific tool to introduce and push the
bearing until it stops, with the shielded side facing
out
- Refit the ball bearing check seeger ring
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
- Use the specific tool to fit and push the roller casing 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 Grease for odometer
transmission gear case
SUSP - 148
LXV 125
LXV 125
Suspensions
Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
Refitting the front wheel
- When refitting, tighten the 5 screws to the specified torque
Locking torques (N*m)
Nut tightening torque 20 to 25 N•m
Handlebar
Removal
Before carrying out these operations, remove the
instrument panel.
- After removing the transmissions and disconnecting the electrical terminals, remove the terminal fixing the handlebar to the steering.
- Check all components and replace faulty parts.
N.B.
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE
THE STEERING, TILT THE HANDLEBAR FORWARD TO
AVOIDING DAMAGING THE TRANSMISSIONS.
Refitting
Carry out the operations in the reverse order to the
removal, observing the prescribed tightening torque.
Locking torques (N*m)
Handlebar lock nut 45 ÷ 50
SUSP - 149
Suspensions
Steering column
Removal
After removing the upper seat, lean the vehicle on
one side and extract the steering tube completely
from the fork.
Specific tooling
020055Y Wrench for steering tube ring nut
Overhaul
- Press and remove the wedging washer with the
help of a pointed end.
- For the second washer, repeat the operation using the punch on the side opposite to the one
shown in the figure.
A = Ø12 Punch
B = Sharp-edged end
- Lubricate the sealing rings with mineral oil and
half-fill the roller casings with grease.
- Insert the seal ring on the pin and the roller bushing with wedging washers at the same time.
- Remove the specific tool, then the part 5 (guiding)
partially ejected in the previous assembly stage;
leave part 4* always fitted.
- Replace part 3 with part 16* on the stem.
- Push, from the handgrip, the wedging washer roller casing - seal ring unit, placing part 16 until it
stops on the swinging hub
SUSP - 150
LXV 125
LXV 125
Suspensions
- Repeat the operation described above using the
tool fitted with part 16 and part 22* instead of part
4 on the stem, on the side opposite the one shown
in the figure to refit the second wedging washer roller casing - sealing ring unit.
* Supplied with the tool
Specific tooling
020021Y Front suspension service tool
Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
Use the tool fitted with parts 3 and 4, as indicated
to fit the pin, and press operating the handgrip,
until wedging the washers on the swinging hub.
- Remove the spacers, part 17, fill with grease the
area between the steering tube and the swinging
hub, and place the dust guard rings in that place.
* Supplied with the tool
N.B.
ASSEMBLE THE LOWER HOUSING ON HE STEERING
TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAMETER.
Specific tooling
020021Y Front suspension service tool
001330Y Tool for fitting steering seats
Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
SUSP - 151
Suspensions
- Fit both dust guard rings «C» on the swinging hub
as shown in the detail drawing «A».
- Connect the swinging hub to the steering tube
with the guide pin, part 5*.
- Use the specific tool fitted with part 3* on its stem
and with part 4 at the bottom of the tool.
- Insert the previously greased pin on the swinging
hub and with the tool handgrip, move part 3 until it
stops on the steering tube.
- After fitting the pin, insert the two spacers, part
17*, slightly hitting with the mallet.
* Supplied with the tool
Specific tooling
020021Y Front suspension service tool
Recommended products
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
- Use the tool fitted with part 20* and part 21* on
its stem as shown in the figure.
- Push the two roller casings with the handgrip until
their bottoms make contact with the pin end.
SUSP - 152
LXV 125
LXV 125
Suspensions
- Use the specific tool, fitted with part 1*, and operate the handgrip until the pin and the Nadella are
simultaneously ejected in the direction opposite
the tool thrusting force.
- To eject the second Nadella, use the tool fitted
with part 2* instead of part 1, on the side opposite
the one shown in the figure.
* Supplied with the tool
Specific tooling
020021Y Front suspension service tool
-The front suspension service operation is useful to replace the connecting parts between the steering
tube and the swinging hub of the front wheel holder, provided that the steering tube and the wheel holder
hub are in excellent conditions.
Refitting
CAUTION
USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING.
SUSP - 153
Suspensions
When fitting the fork, lubricate with the steering
bearing tracks with the recommended grease.
Tighten the lower ring nut "A" and the upper ring
nut "B" to the specified torque
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 C
and +120 C; NLGI 2; ISO-L-XBCIB2.
Locking torques (N*m)
Steering lower ring nut 8 ÷ 10 Steering upper
ring nut 35 ÷ 40
Front shock absorber
SUSP - 154
LXV 125
LXV 125
Suspensions
Removal
- Remove the steering tube
- Remove the shock absorber lower clamps
- Remove the shock absorber upper clamps
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
Locking torques (N*m)
shock absorber lower clamp 20 - 27 shock absorber upper clamp 20 ÷ 30
Shock-absorber - calliper bracket
Removal
- Remove the front wheel hub with the brake disc
- Remove the front shock absorber lower clamps
- Remove the bracket locking seeger ring
- Unscrew the bracket
SUSP - 155
Suspensions
- 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 (N*m)
Lower shock absorber clamp 20 ÷ 27
Overhaul
- The bracket for the shock absorber -calliper attachment has two roller bearings separated one
from the other as shown in the photograph
- Remove the two roller bearings from the bracket
with the specific tool operating on the shock absorber attachment side as shown in the photograph
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
SUSP - 156
LXV 125
LXV 125
Suspensions
- 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 Adaptor 52 x 55 mm
- Assemble a new roller bearing on the shock absorber side and move it until it stops using the
specific tool
Specific tooling
020036Y Punch
- Suitably hold the brake calliper - shock absorber
attachment bracket
- Assemble a new roller bearing on the wheel hub
side and move it until it stops using the specific tool
Specific tooling
020037Y Punch
Refitting
- Refit the parts in reverse 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 Grease for control levers
on the engine
SUSP - 157
Suspensions
LXV 125
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
Steering bearing
Removal
- Use the specific tool both to remove the lower seat of the upper bearing and to remove the upper seat
of the lower bearing fitted on the chassis.
N.B.
TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING JUST USE A SCREWDRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE.
Specific tooling
020004Y Punch for removing fifth wheels from headstock
- Remove the fifth wheel fitting and the dust guard
on the steering tube as shown in figure, using the
specific tool. Proceed giving a few taps with the
mallet.
Specific tooling
020004Y Punch for removing fifth wheels from
headstock
- Refit the fifth wheel fitting and the dust guard on
the steering tube until they stop, using the specific
tool.
Specific tooling
006029Y Punch for fitting fifth wheel seat on
steering tube
Rear
Removing the rear wheel
-Straighten the split pin and remove the cap.
-Remove the wheel acting on the central fixing point.
SUSP - 158
LXV 125
Suspensions
Refitting the rear wheel
- Fit the wheel, tighten the nut to the prescribed
torque.
- Refit the cap and the split pin folding it correctly
as shown in the figure.
Locking torques (N*m)
Locking torque 137 ÷ 152 Nm
Swing-arm
Removal
Remove the swinging arm acting on the three
clamps shown in the figure.
SUSP - 159
Suspensions
Refitting
For rifting, respect the locking torques
Locking torques (N*m)
Part C 33 ÷ 41 Part B 44 ÷ 52 Part A 33 ÷ 41
Shock absorbers
SUSP - 160
LXV 125
LXV 125
Suspensions
Removal
- To replace the shock absorber remove the battery access flap to reach and remove the shock
absorber/ frame anchoring nut. Then remove the
shock absorber/engine anchorage nut.
- When refitting, tighten the shock absorber/chassis anchoring nut and the shock absorber/engine
pin to the prescribed torque.
Locking torques (N*m)
Shock absorber/engine pin torque 33 to 41 N·m
Shock absorber/frame nut torque 20 to 25 Nm
Centre-stand
Replace complete stand
- Undo the screw marked in the figure.
- When refitting, secure to the prescribed torque.
Locking torques (N*m)
Centre stand screw 32 ÷ 40
SUSP - 161
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
LXV 125
Braking system
Front brake calliper
Removal
- Remove the front wheel.
- Remove the pad retention pin.
- Using a pin partially remove the brake pad retention pin.
- Remove the screws fixing the brake calliper to
the crankcase then remove the brake calliper complete with pipe.
- Complete the extraction of the pad retention pin,
the spring and the pads.
N.B.
IF BRAKE CALLIPER REPLACEMENT OR SERVICE IS
NEEDED, BEFORE REMOVING THE CALLIPER CLAMPS
TO THE SUPPORT BRACKET, LOOSEN THE OIL JOINT
FITTING.
Overhaul
- Remove the front brake calliper
- Suitably hold the brake calliper in a clamp
- Remove the two calliper coupling screws as
shown in the photo
- Remove the two pistons from the calliper body
with the aid of short blasts of compressed air
through the brake fluid holes
- Remove the dust ring and the O-ring of each half
calliper.
- Remove the O-rings in the half calliper.
N.B.
WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO
SCRATCH THE HALF CALLIPER SEATS
BRAK SYS - 163
Braking system
- Check there are no scorings on the pistons and
their seats; otherwise, replace them.
- Wash and blow all the components carefully
- Fit the O-rings and new dust guards
- Refit the pistons in their seats being careful to
lubricate with brake fluid
- Recouple the half callipers and lock the two
screws at the specified torque
Locking torques (N*m)
Calliper coupling screw 22 ÷ 27
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 REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COULD COMPROMISE PROPER BRAKE FUNCTIONING AND NOISELESSNESS.
BRAK SYS - 164
LXV 125
LXV 125
Braking system
- Keep the brake pads in contact with the pistons
and insert the calliper in the brake disc.
- Fix the calliper to the fork with the two screws with
elastic washer at the prescribed torque
- Fix the brake pipe joint to the calliper and tighten at the prescribed torque
- Purge the circuit and refit the front wheel
Locking torques (N*m)
Brake calliper support clamping 20 ÷ 25 Nm Brake pipe connection 20 to 25 N•m
Front brake disc
BRAK SYS - 165
Braking system
Removal
- Remove the front wheel
- Remove the front brake calliper
- Remove the hub and the disc operating on the
wheel axle nut
- Adequately support the hub with the disc and operating on the five screws shown in the photograph, 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
BRAK SYS - 166
LXV 125
LXV 125
Braking system
Disc Inspection
- Remove the front wheel
- Use a micrometer to check the disc thickness as
shown in the photograph
- Repeat the measurement in at least 6 points on
the disk
- Remove the front brake calliper
- In order to secure the appropriate tool adequately
use a metal plate with M8 threaded hole and fix it
to one of the two front brake calliper attachment
points
- Place the dial gauge on the disk outer edge
- Make the wheel hub turn and check the disk deviation
Specific tooling
020335Y Magnetic support 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 bolt and the leaf
spring
- Remove the pads
- Check that there are no flaws or warping. If there
are, replace them.
- Check the thickness of the friction material is
more than 1.5 mm. If it is not , replace it
- The replacement must be made with greater residual thickness if the pad has not worn evenly. A
BRAK SYS - 167
Braking system
0.5 mm thickness difference in the residual friction
material is permitted
Refitting
- Insert the brake pads
- Insert the fixing pin being careful to position the
clip with the ends towards the bleed screw as in
the photo.
- Insert the lock on the bolt and then the protection
cover
- Fix the rear 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 ÷ 25 Nm
Fill
BRAK SYS - 168
LXV 125
LXV 125
Braking system
Front
- Remove the rubber cap from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the right-hand brake lever, load the system
and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen
the bleed screw to purge the air. Then tighten the
bleed screw
- Release the brake lever
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE
SYSTEM THROUGH THE PUMP.
N.B.
DURING THE BLEEDING OPERATIONS, 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 COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND
EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
Locking torques (N*m)
System bleed calliper fitting: 20 ÷ 25 Nm
Brake fluid level check
Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
BRAK SYS - 169
Braking system
LXV 125
Front brake pump
Removal
- Remove the two screws fixing the brake pump to
the handlebar indicated in the photograph
- Remove the oil pipes joint from the pump collecting the brake oil in a container
- Remove the connector to the stop light switch
Overhaul
Proceed as follows:
1) Remove the brake lever by loosening the retaining screw; open the cover (2) and take out the diaphragm (3);
2) remove the cap (4) and take out the internal parts in order;
3) Check that:
- The body of the pump shows no signs of internal damage or corrosion;
- The plunger shows no sign of damage or abnormal wear;
- The plunger return spring is in good condition.
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.
1. Reservoir cap screw
2. Reservoir cap.
3. Diaphragm.
4. Bellows.
5. Sealing ring
6. Piston.
7. Gasket.
BRAK SYS - 170
LXV 125
Braking system
8. Spring.
9. Reservoir
Refitting
For refitting purposes carry out the removal operations but in reverse order respecting the tightening
torque and purge the circuit.
Locking torques (N*m)
Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handle bar: 7 ÷ 10 Nm
Rear drum brake
Once the muffler and the wheel have been removed, follow these steps:
1.Remove the shoe spring 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 spring using the specific pliers.
Specific tooling
020325Y Brake-shoe spring calliper
BRAK SYS - 171
Braking system
BRAK SYS - 172
LXV 125
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Seat
Remove the saddle opening cable
Remove the four screws shown in the figure and
the rear seat from the chassis saddle.
Unscrew the two screws of saddle fixing hook cover.
To remove the cable and the sheath:
- Remove the elastic ring and unscrew the cable
end from the seat on the saddle fixing hook.
- Remove the other end of the cable from the fixing
seat on the locking block.
CHAS - 174
LXV 125
LXV 125
Chassis
Instrument panel
- Remove the front grille
- Remove the shield back plate
- Remove the two fixing screws of the instrument
panel.
- Remove the odometer cable.
- Remove the connector of the electric connections
from the instrument panel
Instrument panel lower shell
- Remove the instrument panel
- Remove the handlebar
- Remove the two screws indicated in the figure.
- Remove the screw indicated in the figure, placed
under the handlebar light fitting
CHAS - 175
Chassis
Headlight assy.
- Remove the four fixing screws from the light support.
Knee-guard
- Remove the front grille.
- Unscrew the 2 screws shown in the figure placed
under the front grille.
- Remove the 3 screws shown in the figure, placed
inside the glove-box; they can be reached after
opening the glove-box door.
CHAS - 176
LXV 125
LXV 125
Chassis
Footrest
- Operate on the 3 screws shown in the figure once
the glove-box and fairing have been removed.
Air filter
- Remove the helmet compartment.
- after removing the side fairing, remove the 2
screws fixing the filter box to the engine, indicated
in the figure.
- Remove the two clamps indicated in the figure
CHAS - 177
Chassis
Front mudguard
- Release the front brake pipes from the calliper
and the cable from the odometer
- Remove the steering tube
- Remove the three mudguards-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
CHAS - 178
LXV 125
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
LXV 125
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high-beam lights, low-beam lights, tail and parking lights and their warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel gauge
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 180
LXV 125
Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS
AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO
BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic brake system fluid level.
- Rear hub oil level
- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
PRE DE - 181
Pre-delivery
LXV 125
Static test
Static control after the test ride:
- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 182
INDEX OF TOPICS
TIME
TIME
LXV 125
Time
Engine
ENGINE
1
TIME - 184
Code
001001
Action
engine from frame - removal and refitting
Duration
LXV 125
Time
Crankcase
CRANKCASE
1
2
Code
001133
001153
3
002031
Action
Engine crankcase - Replacement
Half crankcase gasket - Replacement
Rear wheel hub bearings - Replacement
Duration
TIME - 185
LXV 125
Time
Crankshaft
CRANKSHAFT
1
2
TIME - 186
Code
001117
001099
Action
Crankshaft - Replacement
Oil seal, flywheel side - Replacement
Duration
LXV 125
Time
Cylinder assy.
CYLINDER GROUP
1
2
Code
001002
001107
Action
Cylinder-Piston - Replacement
Cylinder / piston - Inspection / cleaning
Duration
TIME - 187
LXV 125
Time
Cylinder head assy.
HEAD UNIT
1
2
3
TIME - 188
Code
001045
001056
001126
Action
Valves - Replacement
Head gasket - change
Head - Replacement
Duration
LXV 125
Time
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT
1
2
3
Code
001044
001148
001049
Action
Camshaft - Replacement
Rocking lever valve - Replacement
Valves - Adjustments
Duration
TIME - 189
LXV 125
Time
Cylinder head cover
HEAD COVER
1
2
3
4
5
6
7
TIME - 190
Code
001089
001088
001159
001093
001097
001091
001074
Action
Head cover - Replacement
Head cover gasket - Replacement
Oil vapour recovery tank - Service
Spark plug - Replacement
Cooling hood - Replacement
Head cover sealing ring
Oil vapour recovery pipe - Replacement
Duration
LXV 125
Time
Chain tensioner
CHAIN TIGHTENER
1
Code
001129
2
001124
Action
Chain tensioner - Service and Replacement
By pass lubrication - Replacement
Duration
TIME - 191
LXV 125
Time
Oil filter
OIL FILTER
1
2
3
4
TIME - 192
Code
001123
001160
003064
001102
Action
Oil filter - Replacement
Oil pressure sensor - Replacement
Engine oil - Change
Net oil filter - Replacement / Cleaning
Duration
LXV 125
Time
Flywheel cover
FLYWHEEL COVER
1
2
Code
001087
001163
3
001161
4
5
001174
001164
Action
Flywheel cover - Replacement
Muffler secondary air connection Replacement
Secondary air filter - Replacement /
Cleaning
SAS valve - Replacement
Crankcase secondary air connection
- Replacement
Duration
TIME - 193
LXV 125
Time
Driven pulley
DRIVEN PULLEY
1
2
3
4
TIME - 194
Code
001155
001022
001012
001110
Action
Clutch bell housing - Replacement
Clutch - Replacement
Driven pulley - Overhaul
Driven pulley - Replacement
Duration
LXV 125
Time
Oil pump
OIL PUMP
1
2
3
4
5
6
7
Code
001051
001125
001042
001112
001130
001100
001122
Action
Belt/Timing chain - Change
Chain guide pads - Replacement
Oil pump - Service
Oil pump - change
Oil sump - Replacement
Oil seal, clutch side - Replacement
Oil pump chain - Replacement
Duration
TIME - 195
LXV 125
Time
Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY
1
2
Code
004125
001156
3
4
003065
001010
TIME - 196
Action
Rear wheel axle - Replacement
Gear reduction unit cover - Replacement
Gear box oil - Replacement
Gear reduction unit - Inspection
Duration
LXV 125
Time
Driving pulley
DRIVING PULLEY
1
2
3
Code
001066
001086
001177
4
001011
Action
Drive pulley - Removal and refitting
Driving half-pulley - Replacement
Variator rollers / shoes - Replacement
Driving belt - Replacement
Duration
TIME - 197
LXV 125
Time
Transmission cover
TRANSMISSION COVER
1
Code
001096
2
001135
3
001065
TIME - 198
Action
Transmission crankcase cover - Replacement
Transmission cover bearing - Replacement
Transmission cover - Removal and
Refit
Duration
LXV 125
Time
Starter motor
ELECTRICAL START-UP
1
2
Code
001020
005045
3
001017
4
5
6
001021
008008
001084
Action
Starter motor - Replacement
Starter motor cable harness - Replacement
Starter sprocket wheel - Replacement
Kick starter - Inspection
Starter spring pack - Replacement
Starter lever - Replacement
Duration
TIME - 199
LXV 125
Time
Flywheel magneto
MAGNETO FLYWHEEL
1
2
3
4
TIME - 200
Code
001109
001173
001067
001058
Action
Cooling fan - Replacement
Rotor - Replacement
Stator - Removal and Refitting
Flywheel - Replacement
Duration
LXV 125
Time
Belt cooling duct
BELT COOLING PIPE
1
2
Code
001170
001132
3
001131
Action
Air manifold - replacement
Transmission air inlet pipe - Replacement
Transmission air intake - Replacement
Duration
TIME - 201
LXV 125
Time
Carburettor
CARBURETTOR
1
Code
001082
2
3
001013
004122
4
5
6
001081
001008
001063
TIME - 202
Action
Carburettor heating resistor - Replacement
Intake manifold - change
Air cleaner carburettor fitting - Replacement
Automatic choke - Replacement
Carburettor - Inspection
Carburettor - Replacement
Duration
LXV 125
Time
Exhaust pipe
MUFFLER
1
2
Code
001009
001095
Action
Muffler - Replacement
Muffler guard - Replacement
Duration
TIME - 203
LXV 125
Time
Air cleaner
AIR CLEANER
1
Code
004122
2
3
4
001014
001015
001027
TIME - 204
Action
Air cleaner carburettor fitting - Replacement
Air filter - Replacement / cleaning
Air filter box - Replacement
Body / air cleaner union - Replacement
Duration
LXV 125
Time
Frame
FRAME
1
2
3
4
5
6
Code
004001
004023
004149
004159
004012
004059
Action
Chassis - Replacement
Shield rim - Replacement
Shield central cover - Replacement
Plates / Stickers - Replacement
Rear side panels - Replacement
Spark plug inspection flap - Replacement
Duration
TIME - 205
LXV 125
Time
Centre-stand
STAND
1
2
TIME - 206
Code
001053
004004
Action
Stand bolt - Replacement
Stand - Replacement
Duration
LXV 125
Time
Footrests
FOOTREST
1
Code
004078
2
004178
Action
Front/rear footrest rubber - Replacement
Footrest - Replacement
Duration
TIME - 207
LXV 125
Time
Rear cover
SHIELD BACK PLATE
1
2
Code
004174
004065
3
4
004081
004082
TIME - 208
Action
Trunk levers - Replacement
Front shield, rear part - Removal and
refitting
Glove box door - Replacement
Trunk gasket - Replacement
Duration
LXV 125
Time
Underseat compartment
HELMET COMPARTMENT
1
2
3
4
Code
004016
005046
004011
004071
Action
Helmet compartment - Replacement
Battery cover - change
Central chassis cover - Replacement
Battery compartment - replacement
Duration
TIME - 209
LXV 125
Time
Plate holder
LICENSE PLATE HOLDER
1
2
3
TIME - 210
Code
004136
005048
005032
Action
License plate support - Replacement
Licence plate holder - Replacement
Licence plate light glass - Replacement
Duration
LXV 125
Time
Mudguard
MUDGUARDS
1
2
Code
004002
004009
Action
Front mudguard - Replacement
Rear mudguard - Replacement
Duration
TIME - 211
LXV 125
Time
Fuel tank
FUEL TANK
1
2
3
Code
004168
005010
004112
4
5
6
004005
004007
004109
TIME - 212
Action
Fuel tank cap - Replacement
Tank float - Replacement
Cock-carburettor hose - Replacement
Fuel tank - Replacement
Fuel valve - Replacement
Fuel tank breather - Replacement
Duration
LXV 125
Time
Rear shock-absorber
REAR SHOCK ABSORBER
1
Code
003007
Action
Rear shock absorber - Removal and
Refitting
Duration
TIME - 213
LXV 125
Time
Steering column bearings
STEERING FIFTH WHEELS
1
2
3
TIME - 214
Code
003002
003073
004119
Action
Steering fifth wheel - Replacement
Steering clearance - Adjustment
Bearing / upper steering fifth wheel Replacement
Duration
LXV 125
Time
Handlebar covers
ODOMETER - HANDLEBAR COVERS
1
2
Code
004053
004018
3
4
005014
005038
5
004019
Action
Spoiler - Replacement
Handlebar front section - Replacement
Odometer - Replacement
Instrument panel warning light bulbs
- Replacement
Handlebar rear section - Replacement
Duration
TIME - 215
LXV 125
Time
Handlebar components
HANDLEBAR COMPONENTS
1
2
3
4
5
6
Code
004066
002037
002071
003001
005017
002024
7
003061
8
002060
9
004162
10
11
002059
002063
TIME - 216
Action
Driving mirror - Replacement
Brake or clutch lever - Replacement
Left hand grip - Replacement
Handlebar - Removal and refitting
Stop switch - Replacement
Front brake pump - Removal and Refitting
Accelerator transmission - Adjustment
Complete throttle control - Replacement
Mirror support and/or brake pump fitting U-bolt - Replacement
Right hand grip - Replacement
Throttle control transmission - Replacement
Duration
LXV 125
Time
Swing-arm
SWINGING ARM
1
Code
001072
Action
Swinging arm - Engine-chassis connection - Replacement
Duration
TIME - 217
LXV 125
Time
Seat
SADDLE
1
2
TIME - 218
Code
004003
004008
Action
Saddle - Replacement
Luggage rack - Replacement
Duration
LXV 125
Time
Turn signal lights
TURN INDICATOR LIGHTS
1
2
3
Code
005002
005012
005067
4
5
6
7
8
005008
005005
005066
005022
005068
Action
Front headlamp - Replacement
Front turn indicator - Replacement
Front turn indicator bulb - Replacement
Front headlamp bulbs - Replacement
Taillight - Replacement
Rear light bulbs - Replacement
Rear turn indicators - Replacement
Rear turn indicator bulb - Replacement
Duration
TIME - 219
LXV 125
Time
Front wheel
FRONT WHEEL
1
2
3
4
5
6
Rear wheel
TIME - 220
Code
004123
003047
003037
003033
002041
003034
Action
Front wheel - Replacement
Front tyre - replace
Front wheel rim- Replacement
Front wheel hub- Replacement
Front brake disc - Replacement
Front wheel hub bearing - Replacement
Duration
LXV 125
Time
REAR WHEEL
1
2
Code
004126
001071
3
4
001016
002002
Action
Rear wheel tyre - Replacement
Rear wheel rim - Removal and Refitting
Rear wheel - Replacement
Rear brake pads/shoes - Replacement
Duration
Electric devices
ELECTRICAL COMPONENTS
1
2
Code
005001
005011
3
4
5
6
7
8
9
005009
005007
005052
001023
001094
001069
005114
Action
Electrical system - Replacement
Start-up remote control switch - Replacement
Voltage regulator - Replacement
Battery - Replacement
Fuse (1) - Replacement
Control unit - Replacement
Spark plug cap - Replacement
HV coil - Replacement
Electrical system - Service
Duration
TIME - 221
LXV 125
Time
Electronic controls
ELECTRICAL CONTROLS
1
2
Code
005039
005006
3
4
5
6
005040
005003
005041
005077
7
8
9
005016
004096
004010
TIME - 222
Action
Headlight switch - Replacement
Light switch or turn indicators - Replacement
Horn button - Replacement
Horn - Replacement
Starter button - Replacement
Emergency stop switch - Replacement
Key switch - Replacement
Lock series - Replacement
Anti-theft lock - Replacement
Duration
LXV 125
Time
Transmissions
TRANSMISSIONS
1
Code
002053
2
002051
3
002049
Action
Rear brake transmission complete Replacement
Odometer transmission assembly Replacement
Odometer cable - Replacement
Duration
TIME - 223
LXV 125
Time
Front suspension
FRONT SUSPENSION
1
2
3
Code
003045
003010
003035
4
5
001064
003044
6
003038
TIME - 224
Action
Steering tube - Replacement
Front suspension - Service
Shock absorber support and brake
calliper - Replacement
Odometer reel - Replacement
Shock absorber cover - Replacement
Front wheel axle - Removal and Refit.
Duration
LXV 125
Time
Braking system
BRAKING SYSTEM
1
Code
002021
2
002007
3
002039
4
002047
5
002002
Action
Front brake hose - Remov. and Refitt.
Front brake shoes/pads - Remov.
and Refitt
Front brake calliper - Removal and
Refitting
Front brake fluid and air bleeding
system - Replacement
Shoes - Rear brake pads - Replacement
Duration
TIME - 225
A
Air filter: 177
B
Battery: 40, 51, 63, 68
Brake: 163, 165, 167, 169–171
Brake fluid: 169
C
Carburettor: 9, 133, 138, 202
F
Fuel: 39, 132, 212
Fuses: 67
H
Headlight: 33, 176
I
Identification: 7
Instrument panel: 175
M
Maintenance: 6, 27
O
Odometer:
Oil filter: 192
S
Saddle:
Shock absorbers: 160
Spark plug: 61
Stand:
Start-up:
T
Tank: 212
Transmission: 8, 39, 76, 89, 98, 198
Tyres: 9
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