VESPA LXV 50 Service Station Manual

SERVICE STATION MANUAL

633860 IT- 633861 EN - 633862 FR - 633863 DE -

633864 ES - 633865 PT - 633866 NL - 633867 EL

Vespa LXV 50

SERVICE STATION

MANUAL

Vespa LXV 50

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

Vespa LXV 50

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-

Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing 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 specific tools, along with the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of 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

C

HARACTERISTICS

T

OOLING

M

AINTENANCE

T

ROUBLESHOOTING

E

LECTRICAL SYSTEM

E

NGINE FROM VEHICLE

E

NGINE

S

USPENSIONS

B

RAKING SYSTEM

C

HASSIS

P

RE

-

DELIVERY

T

IME

CHAR

TOOL

MAIN

TROUBL

ELE SYS

ENG VE

ENG

SUSP

BRAK SYS

CHAS

PRE DE

TIME

INDEX OF TOPICS

C

HARACTERISTICS

CHAR

Vespa LXV 50

Characteristics

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 - 7

Characteristics

Vehicle identification

V

EHICLE IDENTIFICATION

Specification

Engine prefix

Chassis prefix

Desc./Quantity

C381M ÷ 1001

ZAPC38102 ÷ 1001

Vespa LXV 50

Dimensions and mass

CHAR - 8

Specification

Kerb weight

Overall height

Wheelbase

Length

Width

WEIGHTS AND DIMENSIONS

Desc./Quantity

98 ± 5 kg

1180 mm

1280 mm

1800 mm

740 mm

Vespa LXV 50

Characteristics

Engine

Transmission

Specification

Engine type

Bore x stroke

Cubic capacity

Compression ratio

Carburettor

Air filter

Engine idle speed

Starting system

Lubrication

Fuel supply

Cooling

ENGINE

Desc./Quantity

Two-stroke, single cylinder Piaggio Hi-PER2

40 X 39.3 mm

49.40 cc

9.9 ±0.5 : 1

DELL'ORTO PHVA 17.5

Sponge impregnated with fuel mixture (50% SELENIA air filter oil and 50% unleaded petrol).

~ 1800 ± 100 rpm electric starter/kickstarter

With blend and variable oil variable according to the engine revolutions and the throttle valve opening by means of a pump controlled by the driving shaft with toothed belt.

Gravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor.

Forced air circulation.

Specification

Transmission

TRANSMISSION

Desc./Quantity

With automatic expandable pulley variator, torque server, V belt, automatic clutch, gear reduction unit.

Capacities

CAPACITY

Specification

Rear hub oil oil mixer tank

Fuel tank capacity

Electrical system

Desc./Quantity

Quantity: approx. 85 cc

Plastic, capacity ~ 1.2 l

~ 8.5 l (2 l of which is reserve)

Specification

Type of ignition

Ignition advance (before TDC)

Recommended spark plug

Battery

Main fuse

Generator

ELECTRICAL SYSTEM

Desc./Quantity

Capacitive discharge type electronic ignition, with incorporated high voltage coil

Fixed 17° ± 1

CHAMPION RN2C

12V-4Ah

7.5 A

In alternate current with three output sections

Frame and suspensions

Specification

Type

FRAME AND SUSPENSIONS

Desc./Quantity

Unitised body made of stamped plate

CHAR - 9

Characteristics

Vespa LXV 50

Specification

Front suspension

Brakes

Front suspension stroke

Trail (suspension rebounded/compressed)

Rear suspension

Rear suspension travel:

Desc./Quantity

Single arm suspension with swinging arm articulated to the steering tube. Hydraulic double-acting shock absorber and coaxial spring

70 mm

71/68 mm

Single hydraulic double-acting shock absorber, helicoidal coaxial spring. Chassis engine support with swinging arm.

83.5 mm

Specification

Front brake

Rear brake

Wheels and tyres

BRAKES

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

WHEELS AND TYRES

Specification

Front tyre size

Rear tyre size

Front tyre pressure

Rear tyre pressure:

Light alloy rims (Front rim)

Light alloy rims (rear rim)

Desc./Quantity

110/70"-11"

120/70-10"

1.6 bar

2 bar

2.50" x 11"

3.00 x 10"

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST

PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

Secondary air

Follow these steps to clean the sponge filters of the secondary air system:

1) Remove the snap-on plastic cover (1) on the transmission cover using a small screwdriver as a lever on the retaining tongues in order to insert one of the three slots found on that cap.

2) Wash the polyurethane sponge with water and soap, dry all components with compressed air and refit to place. Refit the intake cap respecting the angle reference.

3) Undo the two fixing screws (2) on the aluminium cover of the secondary air housing in order to reach the polyurethane sponge inside that housing; clean as indicated in point 2) and refit all

CHAR - 10

Vespa LXV 50

elements after checking the steel tab is not deformed and/or does not guarantee correct tightness at its fitting; replace if necessary.

N.B.

UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE

TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMI-

NIUM COVERS.

CAUTION

WHILE CARRYING OUT OPERATION 3), ALWAYS CHECK

THE TWO RUBBER COUPLINGS (3) ON ONE END OF THE

SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND

CONTINUITY; IF NECESSARY, REPLACE THEM AND USE

NEW CLAMPS TO FIX THEM.

Carburettor

50cc Version

Dell'Orto

DELLORTO CARBURETTOR

Specification

Type

Diffuser diameter

Regulation reference number

Maximum nozzle:

Maximum air nozzle (on the body):

Tapered pin stamped code:

Pin position (notches from above):

Diffuser:

Minimum nozzle:

Minimum air nozzle (on the body):

Initial minimum mix screw opening:

Starter jet

Starter air nozzle (on the body):

Stroke of starter pin:

Gasoline inlet hole

Desc./Quantity

PHVA 17.5 RD

Ø 17.5

8444

53

Ø 1.5

A22

1

209 HA

32

Free

1 1/2

50

Ø 1.5

11 mm

Ø 1.5

Tightening Torques

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

FRONT BRAKE

FRONT SUSPENSION

Name

Shock absorber upper nut

Front wheel axle nut

Shock absorber upper bracket bolts

Torque in Nm

8 ÷ 12

20 ÷ 25

20 ÷ 25

5 ÷ 6.5

10 ÷ 12

7 ÷ 10

Torque in Nm

20 ÷ 30

75 ÷ 90

20 ÷ 25

Characteristics

CHAR - 11

Characteristics

Vespa LXV 50

Name

Wheel rim screws

Shock absorber lower bolts (°)

STEERING ASSEMBLY

Name

Steering upper ring nut

Steering lower ring nut

Handlebar fixing screw

ENGINE ASSEMBLY

Name

Clutch bell nut (**)

Clutch lock ring nut

Nut locking driving pulley on crankshaft (**)

Start-up lever screw

Flywheel nut (**)

Flywheel fan screws

Half-crank case joint bolts

Bolts holding exhaust pipe to the crankcase

Screws holding the filter box to the crank case

Head nuts

Starter screws

Ignition spark plug

Hub oil drainage cap

Oil hub level dipstick

Rear hub cap screws

Transmission cover screws

Inlet manifold screws

Flywheel hood fixing screws

Cylinder hood fixing screws

Stator clamping screws

Pick-Up clamping screw

Mixer clamping screws

Screw fixing brake lever to the journal on the engine

Name

Swinging arm - engine pin*

Swinging arm pin - frame

Shock absorber - chassis nut (*)

Swinging arm - frame plate shock absorber - engine pin (*)

Rear wheel nut

Side stand fixing screw

Side stand bracket fixing screw

FRAME ASSEMBLY

Overhaul data

Torque in Nm

20 ÷ 25

20 ÷ 27

Torque in Nm

35 ÷ 40

8 ÷ 10

50 ÷ 55

Torque in Nm

40 ÷ 44

55 ÷ 60

40 ÷ 44 Nm

12 ÷ 13

40 ÷ 44

3 ÷ 4

12 ÷ 13

22 ÷ 24

4 ÷ 5

10 ÷ 11

12 ÷ 13

25 ÷ 30

3 ÷ 5

Manual

12 ÷ 13

12 ÷ 13

8 ÷ 9

1 ÷ 2

3.5 ÷ 5

3 ÷ 4

4 ÷ 5

3 ÷ 4

12 ÷ 13

Torque in Nm

33 ÷ 41

44 ÷ 52

20 to 25 Nm

33 ÷ 41

33 to 41 N·m

137 ÷ 152

12 ÷ 20

15 ÷ 20

Assembly clearances

Cylinder - piston assy.

Name

Standard coupling

Standard coupling

Standard coupling

Standard coupling

CHAR - 12

COUPLING BETWEEN PISTON AND CYLINDER

Initials

M

N

O

P

Cylinder

40.005 - 40.012

40.012 - 40.019

40.019 - 40.026

40.026 - 40.033

Piston

39.943 - 39.95

39.95 - 39.957

39.957 - 39.964

39.964 - 39.971

Play on fitting

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

Vespa LXV 50

Name

coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize

Coupling 2nd oversize




Initials

M1

N1

O1

P1

M2

N2

O2

P2

Characteristics

Cylinder

40.205 - 40.212

40.212 - 40.219

40.219 - 40.226

40.226 - 40.233

40.405 - 40.412

40.412 - 40.419

40.419 - 40.426

40.426 - 40.433

Piston

40.143 - 40.15

40.15 - 40.157

40.157 - 40.164

40.164 - 40.171

40.343 - 40.35

40.35 - 40.357

40.357 - 40.364

40.364 - 40.371

Play on fitting

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

0.055 - 0.069

Piston rings

Name

Compression ring

Compression ring 1st oversize

Compression ring 2nd

Oversize

Description

SEALING RING

Dimensions

40

40.2

40.4

Initials

A

A

A

Quantity

0.10 to 0.25

0.10 to 0.25

0.10 to 0.25

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

Name

Connecting rod shoulder washer

Half-shaft, transmission side

Description Dimensions

11.750-0.05

0.5 ± 0.03

13.75+0.040

Initials

A

G

C

Quantity

clearance E = 0.25 to

0.50


0.50 - clearance F =

0.20 to 0.75



0.20 to 0.75

CHAR - 13

Characteristics

Name

Flywheel-side half-shaft

Lining between the shoulders

Cage

Description Dimensions

13.75+0.040

40.64

11.800-0.35

Vespa LXV 50

Initials

D

H

B

Quantity



0.20 to 0.75



0.20 to 0.75

clearance F = 0.20 to

0.75

Slot packing system

This type of engines foresees the use of one size of basic gaskets.

Products

Product

AGIP ROTRA 80W-90

AGIP CITY HI TEC 4T

AGIP FILTER OIL

AGIP CITY TEC 2T

AGIP BRAKE 4

MONTBLANC MOLYBDENUM

GREASE

AGIP GREASE PV2

AGIP GREASE SM 2

AGIP GP 330

RECOMMENDED PRODUCTS TABLE

Description

Rear hub oil

Oil to lubricate flexible transmissions

(brake, throttle control and mixer, odometer)

Oil for air filter sponge

Specifications

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Oil for 2-stroke engines: SAE 5W-40, API

SL, ACEA A3, JASO MA

Mixer oil

Brake fluid

Grease for driven pulley shaft adjusting ring and movable driven pulley housing

Grease for the steering bearings, pin seats and swinging arm

Grease for odometer transmission gear case

Grease for brake control levers, throttle, stand

Mineral oil with specific additives for increased adhesiveness synthetic oil for 2-stroke engines: JASO

FC, ISO-L-EGD

FMVSS DOT 4 Synthetic fluid

Grease with molybdenum disulphide

White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI

2; ISO-L-XBCIB2.

Lithium grease with NLGI 2 molybdenum disulphide; ISO-L-XBCHB2, DIN

KF2K-20

White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2

CHAR - 14

INDEX OF TOPICS

T

OOLING

TOOL

Tooling

Stores code

001330Y

001467Y006

TOOLS

Description

Tool for fitting steering seats

Pliers to extract 20 mm bearings

Vespa LXV 50

001467Y009 Driver for OD 42-mm bearings

001467Y013 Pliers to extract ø 15-mm bearings

001467Y014 Pliers to extract ø 15-mm bearings

001467Y017 Bell for bearings, OD 39 mm

002465Y Pliers for circlips

TOOL - 16

Vespa LXV 50

Stores code

006029Y

020004Y

Description

Punch for fitting fifth wheel seat on steering tube

Punch for removing fifth wheels from headstock

020055Y Wrench for steering tube ring nut

020150Y

020151Y

Air heater support

Air heater

020162Y Flywheel extractor

020163Y Crankcase splitting plate

Tooling

TOOL - 17

Tooling

Stores code

020166Y

020261Y

Description

Pin lock fitting tool

Starter spring fitting

Vespa LXV 50

020265Y Bearing fitting base

020325Y Brake-shoe spring calliper

020329Y MityVac vacuum-operated pump

020330Y Stroboscopic light to check timing

TOOL - 18

Vespa LXV 50

Stores code

020331Y

Description

Digital multimeter

020332Y Digital rev counter

020333Y Single battery charger

020334Y Multiple battery charger

Tooling

TOOL - 19

Tooling

Stores code

020335Y

Description

Magnetic support for dial gauge

Vespa LXV 50

020350Y Electrical system check instrument

TOOL - 20

020359Y

020376Y

020412Y

42x47-mm adaptor

Adaptor handle

15 mm guide

Vespa LXV 50

Stores code

020456Y

Description

Ø 24 mm adaptor

020565Y Flywheel lock calliper spanner

001467Y029 Bell for bearings, O.D. 38 mm

020037Y

020036Y

Punch

Punch

Tooling

TOOL - 21

Tooling

Stores code

020021Y

Description

Front suspension service tool

Vespa LXV 50

TOOL - 22

020038Y

020074Y

Punch

Support base for checking crankshaft alignment

004499Y001 Bearing extractor bell

004499Y006 Bearing extractor ring

Vespa LXV 50

Stores code

004499Y002

Description

Bearing extractor screw

004499Y007 Half rings

020171Y Punch for driven pulley roller bearing

020340Y Flywheel and transmission oil seals fitting punch

020360Y

020358Y

020362Y

Adaptor 52 x 55 mm

37x40-mm adaptor

12 mm guide

Tooling

TOOL - 23

Tooling

Stores code

020363Y

Description

20 mm guide

Vespa LXV 50

020365Y 22 mm guide

020439Y 17 mm guide

020441Y 26 x 28 mm adaptor

020452Y Tube for removing and refitting the driven pulley shaft

TOOL - 24

Vespa LXV 50

Stores code

020451Y

Description

Starting ring gear lock

020444Y Tool for fitting/ removing the driven pulley clutch

Tooling

TOOL - 25

INDEX OF TOPICS

M

AINTENANCE

MAIN

Vespa LXV 50

Maintenance chart

EVERY 2 YEARS

Action

Brake fluid - change

AFTER 1000 KM

50'

Action

Hub oil - change

Oil mixer/throttle linkage - adjustment

Odometer gear - greasing

Steering - adjustment

Brake control levers - greasing

Brake fluid level - check

Safety locks - check

Electrical system and battery - check

Tyre pressure and wear - check

Vehicle and brake test - road test

AFTER 5000 KM, 25000 KM, 35000 KM AND 55000 KM

40'

Action

Hub oil level - check

Spark plug/electrode gap - replacement

Air filter - clean



Brake pads - check condition and wear





AFTER 10000 KM, 50000 KM

95'

Action

Hub oil - change


Air filter - clean

Idle speed - adjustment


Variable speed rollers - replacement


Driving belt - checking





Transmission elements - lubrication


Suspensions - check


Headlight - adjustment



A

FTER

15000 K

M AND

45000 K

M

65'

Maintenance

MAIN - 27

Maintenance

Hub oil level - check


Air filter - cleaning


Driving belt - replacement






SAS box (sponge) (**) - cleaning


(**) See regulations in the «Secondary air system» section

Action

110'

Hub oil - change


Air filter - clean


Cylinder cooling system - check/cleaning


Driving belt - checking


Mixer belt - replacement








Suspensions - check





A

FTER

20000 K

M AND

40000 K

M

Action

A

FTER

30000 K

M

130'

Hub oil - change


Air filter - clean









Flexible brake tubes - replacement




Suspensions - check







Action

MAIN - 28

Vespa LXV 50

Vespa LXV 50

Maintenance

A

FTER

60000 K

M

150'

Hub oil - change


Air filter - clean


Cylinder cooling system - check/cleaning









Flexible brake tubes - replacement




Suspensions - check







Action

Carburettor

- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning.

- Check carefully that the parts are in good condition.

-The throttle valve should move freely in the chamber. Replace valve in case of wear due to excessive clearance.

- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor.

- It is advisable to replace the gaskets at every refit.

WARNING

PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE

GASKETS TO AVOID PETROL LEAKS

1. Automatic starter - 2. Idle air set screw - 3. Idle speed set screw - 4. Throttle valve spring - 5. Throttle valve tapered pin - 6. Throttle valve - 7. Carburettor body - 8. Pin - 9. Min. jet - 10. Float - 11. Max. jet

- 12. Float chamber

MAIN - 29

Maintenance

Checking the spark advance

-Check to be made at over 4000 rpm with stroboscopic gun. The advanced ignition measured must be 17° before the TDC.

- This value is correct when the reference mark on the flywheel hood is aligned with the reference mark on the cooling fan and the phase shifter on the stroboscopic gun is set on 17°.

N.B.

IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS

PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER.

CAUTION

BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK

THE CORRECT KEYING OF THE FLYWHEEL ON THE

CRANKSHAFT.

Specific tooling

020330Y Stroboscopic light to check timing

Spark plug

Place the vehicle on its central stand

- Remove the central cover, indicated in the figure, by undoing the 2 fixing screws;

- Disconnect spark plug HV wire hood;

-Undo the spark plug using the socket wrench;

-Examine the condition of the spark plug, check that the insulating material is whole and measure the distance between the electrodes using a thickness gauge.

-Adjust the distance if necessary by bending the side electrode very carefully.

In the case of defects, replace the spark plug with one of the specified type;

- Engage the spark plug with the due inclination and screw it right down by hand, then do it up with the wrench at the prescribed torque;

-Put the hood on the sparking plug as far as it will go;

MAIN - 30

Vespa LXV 50

Vespa LXV 50

- Refit the central flap.

CAUTION

THE SPARK PLUG MUST BE REMOVED WHEN THE MO-

TOR IS COLD. THE SPARK PLUG MUST BE REPLACED

EVERY 5000 KM. USE OF STARTERS NOT CONFORMING

OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI-

OUSLY DAMAGE THE ENGINE.

Characteristic

Recommended spark plug

CHAMPION RN2C

Electric characteristic

Electrode gap

0.6 to 0.7 mm.

Locking torques (N*m)

Spark plug

25 - 30 Nm

Hub oil

Check

Do the following to check the correct level:

1) Stand the vehicle on the centre-stand on flat ground;

2) Remove the dipstick «A», and dry it with a clean cloth. Reinsert it, screwing it in all the way;

3) Remove the stick and check that the oil level is slightly over the second notch starting from the lower end;

4) Screw the dipstick back in, checking that it is locked in place.

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of

API GL3 specifications

Maintenance

MAIN - 31

Maintenance

Replacement

-Remove the oil cap «A».

- Unscrew the oil drainage cap "B" and drain out all the oil.

- Screw on the drainage plug and fill up the hub with oil (about 85 cc)

Air filter

-Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter.

Cleaning:

-Wash with water and neutral soap.

- Dry with a clean cloth and short blasts of compressed air.

-Saturate with a 50% mixture of gasoline and oil.

-Drip dry the filter and then squeeze it between the hands without wringing.

-Let it dry and refit it again.

CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,

THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE

PISTON AND CYLINDER.


AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Vespa LXV 50

MAIN - 32

Vespa LXV 50

Checking the ignition timing

- Adjust the control cables:

Mix cable: see procedure indicated in "Mixer timing".

Throttle cable: adjust the set screw on the carburettor in such a way that the sheath has no backlash.

Splitter control cable: adjust set screw on the throttle control to the handlebar in such a way that there is no backlash on the throttle control.

Adjust all transmissions in such a way that their sheathings show no sign of backlash.

Mixer Timing

- Using the transmission set screw on the crankcase, with throttle control untwisted, adjust the reference mark on the rotating plate so that it is lined up with the reference mark on the mixer body, as shown in the figure.

While doing this, the engine must be fuelled with a

2 % oil mixture (0.5 litre minimum if the reservoir is empty).

CAUTION

IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN

THE RESERVOIR BLEED THE MIXER AS FOLLOWS: RE-

FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED

TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE

MIXER PIPE FROM THE CARBURETTOR AND LOOSEN

THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE)

UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE

SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO

FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY

PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH

THE RELEVANT METAL CLIP.


AGIP CITY TEC 2T Mixer oil

synthetic oil for 2-stroke engines: JASO FC, ISO-

L-EGD

Braking system

Maintenance

MAIN - 33

Maintenance

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.

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 INEF-

FICIENT.

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 EV-

ERY 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.


AGIP BRAKE 4 Brake fluid


MAIN - 34

Vespa LXV 50

Vespa LXV 50

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 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 EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINI-

MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-

TORY REGULATIONS IN FORCE IN EVERY COUNTRY

WHERE THE vehicle IS USED.

SAS filters inspection and cleaning

Remove the right side fairing by undoing the 2 screws marked «B» indicated in the figure.

Remove the two screws «A» from the aluminium

SAS cover. Release the metal tube from the rubber housing on the cover without extracting the tube from the cover/sleeve. Remove the tab and plastic cover, extract the sponge and wash it in water and soap. Dry it with compressed air before refitting it, making sure to correctly fit the tab in the housing on the two plastic and aluminium covers.

Every time you disassemble the filter, replace the

O-ring seal located in the cover.

Maintenance

MAIN - 35

INDEX OF TOPICS

T

ROUBLESHOOTING

TROUBL

Vespa LXV 50

Troubleshooting

This section makes it possible to find the solutions to use in troubleshooting.

For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

Possible Cause

Fuel nozzles or cock clogged or dirty

Excess of encrustations in the combustion chamber

Lack of compression wear of the piston rings or cylinder

Exhaust pipe clogged due to excessive encrustations

Air filter blocked or dirty

Starter inefficient (stays on)

Clutch slipping

Defective mobile pulley sliding

POOR PERFORMANCE

Transmission belt worn

Carburettor nozzles clogged

Fuel filter on vacuum operated cock blocked

Roller wear; Presence of oil; Dirt

Operation

Dismantle, wash with solvent and dry with compressed air

Remove the encrustations

Check the worn parts and replace them

Replace the exhaust pipe and check the carburation and mixer timer

Clean according to the procedure

Check the mechanical sliding, continuity of the circuit, the presence of power and electrical wiring

Check the centrifugal brake shoe assembly and /or clutch bell and replace if necessary

Check the parts, change the faulty parts and lubricate the driven pulley using only Montblanc-Molibdenum Grease (dis.

498345) grease

Replace


Clean the cock filter

Check the cap with filter is fitted to the transmission cover; clean the speed variator, replace the rollers if worn out

Rear wheel spins at idle

Possible Cause

Idling rpms too high

Clutch fault

Air filter housing not sealed

Starting difficulties

REAR WHEEL

Operation

Check the idling speed and, if necessary, adjust the C.O.

Check the spring/friction mass and the clutch bell

Correctly refit the filter housing and replace it if it is damaged

Possible Cause

Carburettor nozzles clogged or dirty

Faulty fuel cock

Starter inefficient

Battery flat

- Engine flooded.

DIFFICULTY STARTING

Defective spark plug or with incorrect electrode gap

Operation


Check that, at ignition and with throttle untwisted, no petrol flows out the delivery pipe; otherwise, replace the vacuum-operated cock

Check: electric wiring, circuit continuity, mechanical sliding and power supply

Check and if necessary replace the spark plug and the electrode gap

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

Start up keeping the throttle fully open alternating approximately five seconds of turning it with five seconds still. If however it does not start, remove the spark plug, the engine over with the throttle open being careful to keep the cap in contact with the

TROUBL - 37

Troubleshooting

Vespa LXV 50

Possible Cause

Altered fuel characteristics

Faulty spark plug

Intake joint cracked or with a bad seal

Purifier-carburettor fitting damaged

Operation

spark plug and the spark plug grounded but away from its hole.

Refit a dry spark plug and start the vehicle.

Drain off the fuel no longer up to standard; then, refill

Remove the encrustation, restore the plug gap or replace being sure to use the types of spark plug recommended at all times.

Bear in mind that many problems engines have, derive from the use of the wrong spark plug

Replace intake joint and check for correct sealing on the head

Replace

Excessive oil consumption/Exhaust smoke

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause

Excess of encrustations in the combustion chamber

Operation

Remove the encrustations

Engine tends to cut-off at full throttle

ENGINE STOP FULL THROTTLE

Possible Cause

Maximum nozzle dirty - lean mixture

Dirty carburettor

Water in the carburettor

Air filter dirty

Defective floating valve

Tank breather hole obstructed

Operation

Wash the nozzle with solvent and dry with compressed air

Wash the carburettor with solvent and dry with compressed air

Empty the tank through the appropriate bleed nipple.

Clean or replace

Check the proper sliding of the float and the functioning of the valve

Restore the proper tank aeration

Engine tends to cut-off at idle

Possible Cause

Minimum nozzle dirty

Starter that stays open

Reed valve does not close

Wrong idling adjustment

Spark plug defective or faulty

ENGINE STOP IDLING

Operation

Wash the nozzle with solvent and dry with compressed air


Check / replace the reed pack

Adequately adjust the engine idle speed

Replace the spark plug with one with the specified degree and check the plug gap

Excessive exhaust noise

INCREASED NOISINESS

Possible Cause Operation

Secondary metal air pipe deteriorated Check there are no leaks on the hoses on the crankcase and the housing, check that there is a cap with filter and it is correctly fitted to the transmission cover

Good condition of the missing secondary air circuit components Check the individual components and the piping, check the precision of the fitting. Replace the damaged components

TROUBL - 38

Vespa LXV 50

Troubleshooting

High fuel consumption

Possible Cause

Air filter blocked or dirty.

Starter inefficient

HIGH FUEL CONSUMPTION

Operation

Clean according to the procedure


SAS malfunctions

SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUF-

FLER

Possible Cause

Secondary air reed blocking

Secondary air filter clogging

Blockage of the secondary air fitting on the muffler

Operation

Replace

Clean the filter and the housing

Remove the encrustations from the joint being careful not to let the debris fall into the muffler

Transmission and brakes

Clutch grabbing or performing inadequately

Possible Cause

Slippage or irregular functioning

CLUTCH BRAKES

Operation

Check that the masses open and return normally

Check that there is no grease on the masses

Check that the clutch masses' contact surface with the clutch bell is mainly in the middle with characteristics equivalent on the three masses

Check that the clutch bell is not scored or worn abnormally

Never operate the engine without the clutch bell

Check the cap with filter is fitted to the transmission cover

Insufficient braking

BRAKING SYSTEM MALFUNCTION

Possible Cause

Poor braking

Air bubbles inside the hydraulic braking system

Fluid leakage in hydraulic braking system

The brake fluid has lost its properties

Defective sliding of the cables in their sheathes

Brake noise

Operation

The rear (drum type) brake is adjusted by regulating the special adjustment (on the wheel) bearing in mind that, with the control levers in the rest position, the wheels must turn freely.

The braking action should begin when the brake levers are pressed by about a third.

Check the brake pad wear.

If it is not possible to remove any problems by simply adjusting the transmissions, check the brake pads and front brake disc, the brake shoes and the rear drum. If you encounter excessive wear or scoring, make the necessary replacements.

Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever).

Elastic fittings, piston seals or brake pump breakdown, replace

Replace the front brake fluid and top up to the correct level in the pump

Lubricate or substitute

Check the wear of the brake pads and/or shoes

TROUBL - 39

Troubleshooting

Vespa LXV 50

Brakes overheating

BRAKES OVERHEATING

Possible Cause

Defective piston sliding

Brake disc or drum deformed

Operation

Check calliper and replace any damaged part.

Using a dial gauge, check the planarity of the disk with the wheel correctly fitted or the concentricity of the rear drum.


Battery

Possible Cause

Battery

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.

Steering and suspensions

Heavy steering

Possible Cause

Torque not conforming

STEERING HARDENING

Operation

Check the tightening of the top and bottom ring nuts.

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.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause

EXCESSIVE STEERING CLEARANCE

Operation

Check the tightening of the top and bottom ring nuts.

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.

Noisy suspension

Possible Cause

NOISY SUSPENSION

NOISY SUSPENSION

Operation

If the front suspension is noisy, check: the efficiency of the front shock absorbers; the condition of the ball bearings and relevant

TROUBL - 40

Vespa LXV 50

Troubleshooting

Possible Cause Operation

lock-nuts, the limit switch rubber buffers and the movement bushings.

Suspension oil leakage

O

IL LEAKAGE FROM SUSPENSION

Possible Cause

Oil leakage from suspension

Operation

Service the pumping members and check the sleeves and sealing rings are in good conditions. Replace the damaged parts

TROUBL - 41

INDEX OF TOPICS

E

LECTRICAL SYSTEM

ELE SYS

Vespa LXV 50

Electrical system

KEY:

1. Electronic ignition device

2. Spark plug

3. Magneto flywheel

4. Voltage regulator

5. Main fuse

6. Key switch

7. Battery

8. Starter motor

9. Starter remote control

10. Starter button

11. STOP button on front brake

12. STOP button on rear brake

13. Horn button

14. Horn

15. Left turn rear indicator lamp

16. Rear headlight assembly with tail light and stop light bulbs

17. Turn indicator switch

18. Right turn rear indicator lamp

19. Left turn front indicator lamp

ELE SYS - 43

Electrical system

Vespa LXV 50

20. Front headlight assembly with high- and low-beam bulb

A. Tail light bulb

B. Low-/high-beam light bulb

21. Right turn front indicator lamp

22. Light switch

23. High-beam light flash switch

24. Fuel level warning light control

25. Instrument panel

A. turn indicator warning light

B. Fuel level warning light

C. Oil mix level warning light

D. fuel gauge

E. Instrument panel lighting

F. High-beam warning light

G. headlight warning light

H. turn indicator warning light

26. Low oil warning light control

27. Automatic starter

28. Carburettor heater

29. Carburettor heater control device

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 - 44

Vespa LXV 50

Ignition

Electrical system

KEY:

1. Electronic ignition device

2. Spark plug

3. Magneto flywheel

6. Key switch

ELE SYS - 45

Electrical system

Headlights and automatic starter section

Vespa LXV 50

KEY:

3. Magneto flywheel


5. Main fuse

6. Key switch

7. Battery


20. Front headlight assembly with high- and low-beam bulb

A. Tail light bulb

B. Low-/high-beam light bulb

22. Light switch

23. High-beam light flash switch





D. fuel gauge


ELE SYS - 46

Vespa LXV 50




27. Automatic starter

28. Carburettor heater

29. Carburettor heater control device

Battery recharge and starting

Electrical system

KEY:

3. Magneto flywheel


5. Main fuse

6. Key switch

7. Battery

8. Starter motor

9. Starter remote control

10. Starter button

11. STOP button on front brake

12. STOP button on rear brake


ELE SYS - 47

Electrical system


Level indicators and enable signals section

Vespa LXV 50

KEY:

3. Magneto flywheel


5. Main fuse

6. Key switch

7. Battery

24. Fuel level warning light control





D. fuel gauge





ELE SYS - 48

Vespa LXV 50


Devices and accessories

Electrical system

KEY:

3. Magneto flywheel


5. Main fuse

6. Key switch

7. Battery

13. Horn button

14. Horn

15. Left turn rear indicator lamp

17. Turn indicator switch

18. Right turn rear indicator lamp

19. Left turn front indicator lamp

21. Right turn front indicator lamp





ELE SYS - 49

Electrical system

Vespa LXV 50

D. fuel gauge





Checks and inspections

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 irreparably damaged.

Ignition circuit

1) Check the condition of the spark plug (clean it with a metal brush, remove deposits, blast it with a jet of compressed air and replace it if necessary).

2) Without removing the stator, carry out the following checks:

After visually checking the electrical wiring, perform measurements on the loading coil, the pickup and the continuity using the appropriate tester.

If checks on the loading reel, pickup and continuity show abnormalities, replace the stator; otherwise replace the central unit.

Remember that disconnections due to replacement of the central unit must be done with the engine off.


020331Y Digital multimeter

1

1

P

ICK

-U

P CHECK

Specification

Red cable (1) and White cable (2)

R

ELOADING COIL CHECK

Specification

Red cable (3) and Green cable (4)

Desc./Quantity

90 ÷ 140 Ohm

Desc./Quantity

800 ÷ 1100 Ohm

ELE SYS - 50

Vespa LXV 50

Electrical system

1

2

Specification

White cable - Engine

White cable - Frame

C

ONTINUITY CHECK

Voltage regulator check

Voltage regulator

The malfunctioning of the voltage regulator might cause the following problems depending on the type of fault:

1) Lighting system bulbs burn out.

2) Lighting system is not working.

3) Battery overcharges (the main fuse blows).

4) Battery not recharging.

5) Turn indicators not working.

6) Oil and fuel check warning light not working.

Remedies

FAULT 1: Bulbs burn out

Check that the control voltage is between 13V and

14.5V at 5000 rpm with the lights on.

Check that the control voltage is <16V at 5000 rpm with the lights off.

Replace the voltage regulator if control voltages are over >16V.

FAULT 2: Lighting system not working

a) Check that voltage to stator is correctly supplied: disconnect the regulator connector and place the tester to detect alternating voltages between the connection of the grey-blue cable (2) and the black cable (6) to check that the voltage supplied at 3000 r/1' is within 25 - 30 V as indicated in the figure. If faults are detected, replace the stator.

b) If no faults are detected with these controls, replace the regulator.

c) If functioning is still not correct even when the regulator has been replaced, check the connections of the electrical system.

Desc./Quantity

Continuity

Continuity

ELE SYS - 51

Electrical system

FAULT 3: Blown main fuse

After checking that there are no short-circuits in the system towards earthing with the engine off and the regulator connector detached, replace the regulator because it is certainly inefficient, and replace the protection fuse.

Following the replacement, measure the current and the recharging voltage on the battery end. The values detected must be 1.5 ÷ 2 A and 13 V at 3000 rpm.

FAULT 4: Battery does not recharge

a) Make the scooter move and disconnect the battery positive lead. Place the tester to detect alternating voltages between the connection of the yellow cable (8) on the regulator and the black cable (6) to check that the voltage supplied by the generator at 3000 r/1' is within 26 ÷ 30 V. In case of irregularities, replace the stator; otherwise, proceed to point b).

b) Yellow cable (1) connected to the regulator. Insert an ammeter between the Red cable (2) of the stator and the battery and check, with the tester, that the current supplied at 3000 r/1' and with the battery between 12 and 13 V is about 1.5 ÷2 Ampere.

If the values detected are lower than those specified, replace the regulator.

Before carrying out the checks on the regulator and the corresponding system, it is always good practice to check that there is continuity between the black cable and the earthing.

Vespa LXV 50

ELE SYS - 52

Vespa LXV 50

FAULT 5: Turn indicators not working

If the turn indicators do not work, do the following:

Remove the regulator connector, and insert the ends of the tester between contact 5 (yellow) and the earthing.

- Turn the key switch to ON and check that the battery is getting voltage. If no voltage is detected, check the wiring and the contacts on the key switch and on the battery.

Repeat the same procedure with the ends of the tester inserted between contact 5 (yellow) and 6

(black) and check there is voltage in the battery with the key switch set to ON. If there is no voltage, check the cable harness.

If the above tests have positive results, jump the contacts 5 (yellow) and 7 (blue black) on the connector, set the key switch to ON and turn the turn indicator switch left and right to see when the lights are steadily on (as they are powered directly from the battery). If even after this operation the turn indicators fail to turn on, check the wiring is not damaged and switch works properly; If these last two tests have a positive result, replace the regulator because it is certainly not functioning properly.

FAULT 6:Oil reserve check warning light not working

Disconnect the voltage regulator connector.

- Supply 12V to the terminal marked with number

5; with a digital tester check that the terminal number 4 has a similar output (12V) for about 5 seconds.

- If no voltage is detected for terminal number 4, replace the regulator.

Electrical system

ELE SYS - 53

Electrical system

Vespa LXV 50

- If there is voltage for terminal number 4, check both the cable harness and the bulb of the oil warning light.


020331Y Digital multimeter

Fuses

The electrical system is protected by a valve fuse

«B» located to the left of the battery compartment.

The ignition system and rear taillight are not protected by fuses. Before replacing a blown fuse, find and solve the problem that caused it to blow. Do not substitute the fuse with any alternative form of conductor

CAUTION

IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYS-

TEM, NEVER DISCONNECT THE WIRING WHILE THE EN-

GINE IS RUNNING. DO NOT TIP THE SCOOTER TOO MUCH

IN ORDER TO AVOID DANGEROUS LEAKAGE OF BAT-

TERY ELECTROLYTE.

Electric characteristic

Fuse

Fuse valve: 7.5 A

1

2

3

4

5

6

7

8

Specification

High/low beam light bulb

Front tail light bulb

Front turn indicator bulb

Rear turn indicator light bulb

Stop and tail light bulb

12V - 2W warning light bulbs

12V - 2W warning light bulbs

Instrument panel light bulbs

BULBS

Desc./Quantity

Type: Spherical

Power: 12V 35/35W

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

Quantity: 2

Type: All glass

Function: Turn indicators, engine oil, fuel reserve, taillight, high-beam light

Quantity: 5

Type: All glass

Power: 12V 1.2W

ELE SYS - 54

Vespa LXV 50

Electrical system

Specification Desc./Quantity

Quantity: 4

Sealed battery

INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.

- If the voltage exceeds 12.60 V, the battery may 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 equal to 14.40÷14.70V

-Initial charge voltage equal to 0.3÷0.5 for nominal capacity

-Duration of the charge: 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 nominal capacity of the battery

-Duration of the charge: 5 h

WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF

RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.

IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON-

TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

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 - 55

Electrical system

The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are:

1) Check the level of the electrolyte

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's electrical system: the battery works overcharged and is subject to quick wear.

2)Load status check

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.

After charging the battery, check each element electrolyte level and density. 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 earth wire (black) marked (-) must be connected to the - negative terminal while the other two red wires marked (+) must be connected to the terminal marked with the + positive sign.

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

ELE SYS - 56

Vespa LXV 50

Vespa LXV 50

Electrical system supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).

4) Cleaning the battery

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 the battery away from naked flames or sparks when charging.

Remove the battery from the vehicle removing the negative clamp first.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN

THAT RECOMMENDED.

USING A FUSE OF UNSUITABLE RATING MAY SERIOUS-

LY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

DRINKING WATER CONTAINS MINERALS THAT CAN BE

EXTREMELY HARMFUL TO THE BATTERY: USE DISTIL-

LED WATER ONLY.

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.


020333Y Single battery charger

020334Y Multiple battery charger

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° Bé, 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 with the specific battery charger (single) or (multiple) at a density of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corresponding to 31º Bé, and 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 in the vehicle ensuring the connections between the wiring and the battery terminals are correct.

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 CORRE-

SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO

ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.


020333Y Single battery charger

ELE SYS - 57

Electrical system

020334Y Multiple battery charger

Vespa LXV 50

ELE SYS - 58

INDEX OF TOPICS

E

NGINE FROM VEHICLE

ENG VE

Engine from vehicle

Vespa LXV 50

Removal of the engine from the vehicle

Removing the engine from the chassis

-Disconnect the battery.

-Remove the muffler assembly.

- Remove the rear wheel.

- Remove the mechanical transmission of the rear brake.

-Disconnect the electric terminals.

- Remove the throttle grip and mixer transmissions.

- Disconnect the hoses (petrol-oil-vacuum-operated cock control).

WARNING

Be very careful when handling fuel.

CAUTION

When installing the battery, first attach the positive cable and then the negative cable.

WARNING

Wear safety goggles when using hitting tools.

ENG VE - 60

INDEX OF TOPICS

E

NGINE

ENG

Engine

Automatic transmission

Transmission cover

- Loosen the 15 screws and remove the transmission cover with the aid of a mallet.

N.B.

THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT

FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY

AND THE BEARING HOUSED ON THE CRANKCASE.

Kickstart

- Remove the screws shown in the figure and remove the engine starting lever.

- For the assembly, work in reverse and tighten the screws to the prescribed torque..


Starter lever replacement

12 to 13 Nm

- Upon refitting, apply the recommended grease to the bushing, to the spring and along the toothed sector.

- Use the special tool for the charging of the spring, as shown in the figure.

- Refit the seeger ring after checking that it is in good condition.


020261Y Starter spring fitting


AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

ENG - 62

Vespa LXV 50

Vespa LXV 50

Engine

- Remove the seeger ring located on the exterior of the crankshaft.

- Dismantle the dog gear from its seat, slackening the tension that the toothed sector applies to it by means of the spring; to do this, it is necessary to rotate the toothed sector slightly (see the figure).

CAUTION

WHILE REMOVING THE TOOTHED SECTOR, BE VERY

CAREFUL OF THE SPRING TENSION: IT COULD CONSTI-

TUTE A HAZARD FOR THE OPERATOR.

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

N.B.

IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-

AMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing

-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED

SURFACE.

ENG - 63

Engine

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the whole of the driven pulley assembly.

N.B.

THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE

PULLEY MOUNTED.


020565Y Flywheel lock calliper spanner

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the inner diameter of the clutch bell.

Characteristic

Clutch bell diameter/standard value

Ø 107+0.2 +0 mm

Clutch bell diameter/max. value allowed after use

Ø 107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position

«A» from the outside, insert the entire driven pulley in the tool and put the central screw under stress.

CAUTION

THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW

IS TIGHTENED UP TOO FAR.

Vespa LXV 50

ENG - 64

Vespa LXV 50

- Using a 34 mm socket wrench remove the clutch locking nut.

- Loosen the central screw thereby undoing the driven pulley unit

- Separate the components.


020444Y Tool for fitting/ removing the driven pulley clutch

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 CEN-

TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-

ENT 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.

Engine

ENG - 65

Engine

- Remove the three guide pins and the mobile half pulley.

Removing the driven half-pulley bearing

- Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley.

CAUTION

POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-

ERS BETWEEN THE END OF THE BEARING AND THE

BUILT IN SEALING RING.


001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch housing by means of the special tool.

N.B.

PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO

DEFORM THE SLIDING SURFACE OF THE DRIVING BELT


020376Y Adaptor handle

020363Y 20 mm guide

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work surface of the belt. If there are, replace the halfpulley..

- Make sure the bearings do not show signs of unusual wear.

- Measure the external diameter of the pulley bushing.

Characteristic

ENG - 66

Vespa LXV 50

Vespa LXV 50

Engine

Stationary driven half-pulley/Standard diameter

Ø 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diameter admitted after use

Ø 33.96 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

Mobile driven half-pulley/ Maximum diameter allowed

Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile half-pulley.

- Fitting the half-pulley on the bushing.


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

- 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 gr. of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.


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

ENG - 67

Engine

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible from the outside.

CAUTION

PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT

DAMAGE TO THE THREADED END WHILE THE BEARINGS

ARE BEING FITTED.



020456Y Ø 24 mm adaptor

020362Y 12 mm guide

020171Y Punch for Ø 17 mm roller case

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley does not show signs of deformation

- Measure the free length of the spring

Characteristic

Standard length

118 mm

Minimum length allowed after use

XXXX

Refitting the clutch

- Preassemble the driven pulley group with spring, sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar.

ENG - 68

Vespa LXV 50

Vespa LXV 50

- Reassemble the nut securing the clutch and tighten to the prescribed torque.

CAUTION

SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-

ET WRENCH WITH SMALL CHAMFER.

CAUTION

POSITION THE NON-CHAMFERED SURFACES OF THE

NUT IN CONTACT WITH THE CLUTCH


Nut locking clutch unit on pulley

55 ÷ 60 Nm

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell and the nut, using the specific tool.




Driven pulley shaft nut

40 to 44 Nm

Drive-belt

- Make sure the driving belt is not damaged and does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

Transmission belt/Minimum width

17.5 mm

Engine

ENG - 69

Engine

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer, then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

Vespa LXV 50

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.


020451Y Starting ring gear lock

Mixer gears and belt

- Remove gear and belt.

CAUTION

PAY PARTICULAR ATTENTION TO NOT TOUCHING OR

BENDING THE BELT BECAUSE THIS COULD BREAK SUD-

DENLY DURING OPERATION.

CAUTION

ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET

INTO THE INNER BUSHING OF THE MIXER CONTROL

GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON

THE CRANKCASE PIN.

N.B.

REPLACE THE BELT EVERY 20000 KM.

Inspecting the rollers case

1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation.

2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders.

ENG - 70

Vespa LXV 50

4) Check the integrity of the sliding blocks of the contact plate.

- Check that the internal bushing shown in the figure is not abnormally worn and measure inside diameter «A».

- Measure outside diameter «B» of the pulley sliding bushing shown in the figure.

CAUTION

DO NOT LUBRICATE OR CLEAN THE BUSHING.

Characteristic

Driving pulley / Maximum diameter:

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

Refitting the driving pulley

- Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.

N.B.

IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO

THAT THE WORDS CAN BE READ IN CASE IT DOES NOT

SHOW A FITTING SIDE.

- Refit the components of the assembly (roller container assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut).

- With the specific tool, tighten the lock nut to 20

Nm and then perform a final 90° locking in order to prevent the rotation of the driving pulley.

N.B.

REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT

CAUTION

UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-

MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN

Engine

ENG - 71

Engine

ORDER TO AVOID WRONG TIGHTENING AND CONSE-

QUENTLY DAMAGING THE CRANKSHAFT KNURLING.


020451Y Starting ring gear lock


Crankshaft pulley nut

18 to 20 + 90° Nm

For 25 km/h engine type versions, the limit washer is 5.5 mm thick

End gear

Removing the hub cover

• Remove the transmission cover

• Remove the clutch assembly

• Discharge the rear hub oil.

• Remove the 5 screws indicated in the figure.

• Remove the hub cover with driven pulley shaft.

See also

Refitting the clutch

Removing the wheel axle

- Remove the intermediate gear and the complete gear wheel axle.

- When removing the intermediate gear pay attention to the various shim adjustments.

Vespa LXV 50

ENG - 72

Vespa LXV 50

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.

- Remove the bearing by pushing from the outside towards the inside of the gear compartment, using the appropriate punch.


020363Y 20 mm guide


020358Y 37x40-mm adaptor

Removing the driven pulley shaft bearing

- Remove the seeger ring inside the cover.

- Remove the oil seal from the outside.

- Remove the centring dowels and position the cover on a plane.

- Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.


020452Y Tube for removing and refitting the driven pulley shaft

- Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the figure. Expel the driven pulley shaft with the aid of a press.



Engine

ENG - 73

Engine

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.

- Check capacity ( A ) of the transmission gear

(wear, deformations, etc.)

- Check the pulley shaft seating: Superficial wear

( B ) may indicate irregularities in the crankcase seatings or in the pulley shaft capacities

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.

Refitting the driven pulley shaft bearing

- Support the inner track of the bearing from the outside of the hub cover with the specific tool positioned under the press and insert the driven pulley axle.

- Refit the oil seal flush with the cover.



• Heat the hub cover and insert the bearing with the specific punch.

• Fit the snap ring with the concave or radial part on the bearing side.

N.B.

FIT THE BALL BEARING WITH THE SHIELD FACING THE

OIL SEAL.


020151Y Air heater


020439Y 17 mm guide

020358Y 37x40-mm adaptor

ENG - 74

Vespa LXV 50

Vespa LXV 50

Refitting the wheel axle bearing

- Heat the half crankcase on the transmission side using a thermal gun.

- After lubricating its outer strip, insert the bearing with the special adapter with the aid of a hammer.

- Refit the seeger ring and the oil seal using the 42 x 47 mm adapter and the handle.




020363Y 20 mm guide

020359Y 42x47-mm adaptor

Refitting the ub cover

- Refit the whole wheel axle.

- Refit the intermediate gear paying attention to the two shim thicknesses.

- Apply LOCTITE 510 for surfaces to the hub covers and refit the same with driven pulley shaft.

- Refit the 5 screws and tighten them to the specified torque.

N.B.

CLEAN THE CONTACT SURFACES OF THE HUB COVER

AND THE HALF CRANKCASE OF RESIDUE FROM PREVI-

OUS GASKETS BEFORE APPLYING A NEW ONE.


Locking torque:

11 to 13 Nm

Flywheel cover

Engine

ENG - 75

Engine

Cooling hood

- Remove the four fixings shown in the figure.

- Remove the fan cover

- Remove the oil piping retention band from the hood

- Remove the 2 screws shown in the figure

Cooling fan

- Remove the cooling fan by acting on the three fixings indicated in the figure.

Vespa LXV 50

ENG - 76

Vespa LXV 50

Removing the stator

- Remove the three stator fixings shown in the photo

- Remove the two pick-up fixings shown in the photo

- Remove the stator with the wiring

Engine

Refitting the stator

- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.

N.B.

THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE

CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM-

BLY.


Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4

Flywheel and starting

Removing the starter motor

Remove the two clamps shown in the figure

ENG - 77

Engine

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

- Extract the flywheel with the extractor.



020162Y Flywheel extractor

Inspecting the flywheel components

- Check the condition of the flywheel and any distortions that might cause rubbing on the stator and on the Pick-Up.

Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key properly.

- Lock the flywheel nut at the prescribed torque

- Check the Pick-Up air gap.

- The air gap may not be modified in the fitting of the Pick-Up.

- Other values derive from deformations visible on the Pick-Up support.

ENG - 78

Vespa LXV 50

Vespa LXV 50

N.B.

A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO

A VARIATION IN THE IGNITION ADVANCE SUCH AS TO

CAUSE PINGING, KNOCKING ETC.


Flywheel nut

40 to 44 N.m

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.


Starter motor screws

11 ÷ 13

Cylinder assy. and timing system

Removing the intake manifold

Use an anti-tampering TORX spanner to remove the two clamping screws of the intake manifold

Removing the cylinder head

Remove the 4 screws shown in the figure

Engine

ENG - 79

Engine

Removing the cylinder - piston assy.

Remove the cylinder very carefully

Vespa LXV 50

Remove the snap rings and remove the pin

CAUTION

AFTER EACH REMOVAL OPERATION REPLACE THE PIN

RETENTION SNAP RINGS

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 CRANK-

SHAFT" CHAPTER".

Characteristic

Rod small end: standard diameter

17 +0.011-0.001

Rod small end: maximum allowable diameter

17,060 mm

ENG - 80

Vespa LXV 50

Inspecting the wrist pin

- Check the wrist pin external diameter using a micrometer

Characteristic

Wrist pin: standard diameter

12 +0.005 +0.001 mm

Inspecting the piston

- Measure the bearings on the piston using a bore meter

- Calculate the piston-pin coupling clearance.

Characteristic

Wrist pin housing: standard diameter

12 +0.007 +0.012

Wrist pin housing: standard clearance

0.002 ÷ 0.011 mm

- Measure the outer diameter of the piston, perpendicular to the pin axis.

- Take the measurement in the position shown in the figure

To classify the cylinder-piston fitting, check the appropriate table

See also

Cylinder - piston assy.

Engine

ENG - 81

Engine

Vespa LXV 50

Inspecting the cylinder

- Check that the cylinder does not show seizures.

Otherwise, replace it or adjust it respecting the allowable increases

- Measure the internal diameter of the cylinder with a bore meter, according to the directions given in the figure

- Check that the fitting surface with the head is not dented or distorted.

To classify the cylinder-piston fitting, check the appropriate table

See also

Cylinder - piston assy.

Inspecting the piston rings

- Alternatively insert the two sealing rings in the cylinder

Using the piston, insert the seals perpendicularly to the cylinder axis.

- Measure the opening of the sealing rings using a thickness gauge as shown in the photograph

- If the values are higher than the values prescribed in the chart, substitute the rings

Removing the piston

- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.

-Push detail 2 into detail 1 until the stop and extract detail 2.

- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3 all the way in.

N.B.

REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM

THE REMOVAL OPERATIONS


020166Y Pin lock fitting tool


Locking head nuts: 10 to 11 N·m

ENG - 82

Vespa LXV 50

- Use new wrist pin snap rings.

- Use new cylinder base gasket.

- Before refitting carefully clean all the surfaces.

- Use oil to be mixed during the fitting of the piston and the cylinder.

CAUTION

POSITION THE ARROW PRINTED ON THE PISTON

CROWN TOWARDS THE EXHAUST OPENING.

THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON

THE PISTON WITH THE SPECIFIC TOOL


AGIP CITY TEC 2T Oil

Recommended oil

Engine

ENG - 83

Engine

Inspecting the timing system components

CAUTION

CHECK THE CORRECT REED UNIT SEAL; NO LIGHT

MUST PASS BETWEEN THE SUPPORT AND LAMELLA.

Vespa LXV 50

Crankcase - crankshaft

Splitting the crankcase halves

Remove the eight crankcase union fasteners.

Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side


020163Y Crankcase splitting plate

ENG - 84

Vespa LXV 50

Removing the crankshaft

- Install the specific tool on the half crankcase on the transmission side using four M6 screws of an adequate length.

- Remove the crankshaft from the transmission side half crankcase



Removing the crankshaft bearings

The bearings can stay on either the half crankcase or the crankshaft indifferently

- Using the special tool, remove any bearings that have been left on the crankshaft

N.B.

The half rings must be inserted on the bearings with a few mallet blows.


004499Y001 Bearing extractor bell

004499Y006 Bearing extractor ring

004499Y002 Bearing extractor screw

004499Y007 Half rings

- Using the specific tool remove any bearings left on the half crankcase


001467Y007 Driver for OD 54 mm bearing

001467Y006 Pliers to extract 20 mm bearings

Engine

ENG - 85

Engine

Refitting the crankshaft bearings

Heat the bearings in an oil bath at around 150°C and fit them on the crankshaft, if necessary using a section of tube that acts on the bearing's inner track


020265Y Bearing fitting base

Inspecting the crankshaft alignment

With the specific tool shown check that the eccentricity of the surfaces of diam. «A»-«B»-« C» are within 0.03 mm. (reading limit on the dial gauge); in addition, check the eccentricity of diam. «D», for which a maximum reading of 0.02 mm is permitted.

In the case where eccentricity is not much above prescribed levels, straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp (with an aluminium bushing) as required..


020335Y Magnetic support for dial gauge

020074Y Support base for checking crankshaft alignment

Refitting the crankshaft

- Position the transmission side half crankcase on two wooden supports

- Using a thermal gun, heat the bearing seat to about 120°

ENG - 86

Vespa LXV 50

Vespa LXV 50

- Firmly insert the crankshaft until the bearing reaches the end-of-stroke stop

- Let the temperature of the half crankcase settle at the temperature of the crankshaft.

- Again install the special crankcase separation plate NOT installing the crankshaft protection

- During the assembly phase keep the central thrust screw loose.

- Take the four clamping screws to the end of the stroke and loosen them again with the same angle

(e.g. 90°)

- When the temperature has settled, preload the thrust screw of the tool manually until the ball bearing clearance is cancelled out.



Refitting the crankcase halves

- Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the surface using a suitable solvent (e.g. trichloroethylene)

- Heat the flywheel-side half crankcase with a thermal gun.


Loctite 510 Liquid sealant

Gasket

Engine

ENG - 87

Engine

- Keeping the half crankcase on the transmission side, insert the flywheel side half crankcase with a clean precise movement

- Insert at least three clamping screws and tighten up rapidly

- Insert the other 5 screws and tighten them to the specified torque.

Locking torques (N*m) crankcase coupling screws

11 - 13

- Move the crankcase separation plate in a position back from the one indicated in the figure

- Install the special magnetic support with dial gauge at the end of the crankshaft

- Check the axial clearance of the crankcase

If this is not within the maximum limit allowed, repeat the crankcase coupling procedure



Characteristic

Axial clearance with warm crankcase

0.10 ÷ 0.12 mm

Axial clearance with cold crankcase

0.06 to 0.08 mm

Limit value with cold crankcase

0.02 ÷ 0.03 mm

Lubrication

Crankshaft oil seals

Vespa LXV 50

ENG - 88

Vespa LXV 50

Refitting

- Install a new flywheel-side oil seal only with the special tool's punch

The flywheel-side oil seal is recognised by its smaller diameter

N.B.

THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE

WITH THE FITTED WRENCH


020340Y Flywheel and transmission oil seals fitting punch

- Install a new transmission side oil seal using the special tool with adapter ring.

The transmission-side oil seal is recognised by the larger diameter


020340Y Flywheel and transmission oil seals fitting punch

Oil pump

Removal

- Remove the 2 screws shown in the figure

Engine

ENG - 89

Engine

Remove the tube passage seal from the crankcase shown in the figure

Refitting

To refit, perform the steps in the reverse direction to disassembly

Remember to drain after refitting using the screw shown in the figure

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 INCOR-

RECT NUMBER OF REVS OR BY THE WRONG POSITION

ENG - 90

Vespa LXV 50

Vespa LXV 50

OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OB-

TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-

LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY

REDUCED FOR THE PURPOSE OF ENHANCING THE SUC-

TION PULSATION AND THEREBY GUARANTEE A CON-

STANT TAP FLOW RATE.


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.

Engine

ENG - 91

INDEX OF TOPICS

S

USPENSIONS

SUSP

Vespa LXV 50

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.

Suspensions

Front wheel hub overhaul

- Remove the ball bearing check seeger ring indicated in the photograph

Extract the ball bearing using the specific tool


001467Y014 Pliers to extract ø 15-mm bearings

001467Y017 Bell for bearings, OD 39 mm

SUSP - 93

Suspensions

- Remove the oil seal on the roller bearing side using a screwdriver.

- Remove the roller bearing using the specific tool



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




020359Y 42x47-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


020038Y Punch


AGIP GREASE MU3 Grease for odometer transmission gear case

SUSP - 94

Vespa LXV 50

Vespa LXV 50

Soap-based lithium grease with NLGI 3; ISO-L-

XBCHA3, DIN K3K-20

Refitting the front wheel

- When refitting, tighten the 5 screws to the specified torque


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.


Handlebar lock nut

45 ÷ 50

Suspensions

SUSP - 95

Suspensions

Steering column

Removal

After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork.


020055Y Wrench for steering tube ring nut

Overhaul

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 DIAME-

TER.


020021Y Front suspension service tool

001330Y Tool for fitting steering seats


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 - 96

Vespa LXV 50

Vespa LXV 50

- 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

- 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.








- 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.

Suspensions

SUSP - 97

Suspensions








- 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.

Vespa LXV 50

- 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.




-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.

SUSP - 98

Vespa LXV 50

- 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.

Suspensions

A = Ø12 Punch

B = Sharp-edged end

Refitting

CAUTION

USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING.

SUSP - 99

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


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.


Steering lower ring nut

8 ÷ 10

Steering upper ring nut

35 ÷ 40

Vespa LXV 50

Front shock absorber

SUSP - 100

Vespa LXV 50

Removal

- Remove the steering tube

- Remove the shock absorber lower clamps

- Remove the shock absorber upper clamps

Suspensions

Refitting

To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.


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 - 101

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


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



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

Vespa LXV 50

SUSP - 102

Vespa LXV 50

- Suitably hold the brake calliper - shock absorber attachment bracket

- Fit a new oil seal and move it until it stops using the specific tool



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


020036Y Punch

Suspensions

- 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


020037Y Punch

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 SCREW-

DRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE.


020004Y Punch for removing fifth wheels from headstock

SUSP - 103

Suspensions

- 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.


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.


006029Y Punch for fitting fifth wheel seat on steering tube

Rear

Removing the rear wheel

- Use a screwdriver as a lever between the drum and the cover.

-Straighten the split pin and remove the cap.

-Remove the wheel acting on the central fixing point.

WARNING

-ALWAYS USE NEW SPLIT PINS FOR REFITTING.

Vespa LXV 50

SUSP - 104

Vespa LXV 50

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 torque

137 ÷ 152 Nm

Swing-arm

Removal

Remove the swinging arm acting on the three clamps shown in the figure.

Suspensions

SUSP - 105

Suspensions

Vespa LXV 50

Refitting

For rifting, respect the locking torques


Part C

33 ÷ 41

Part B

44 ÷ 52

Part A

33 ÷ 41

Shock absorbers

SUSP - 106

Vespa LXV 50

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.


Shock absorber/engine pin torque

33 to 41 N·m

Shock absorber/frame nut torque

20 to 25 Nm

Suspensions

SUSP - 107

INDEX OF TOPICS

B

RAKING SYSTEM

BRAK SYS

Vespa LXV 50

Braking system

1. Tank cover.

2 - Pump body.

3 - Brake lever.

4 - Pump plunger.

5- Oil delivery hose.

6 - Protection cap for air bleed screw.

7- Calliper.

8- Dust guard

9- Piston sealing ring.

10- Piston.

11 - Brake pad.

12 - Brake disc.

Front brake calliper

Removal

- Detach the oil brake hose from calliper, pouring the fluid inside a container.

- Remove the mountings indicated in the figure.

- When refitting, tighten the nuts to the prescribed torque.

- Bleed the system.


Calliper tightening screw

20 ÷ 25 Nm

Brake fluid tube calliper

20 ÷ 25 Nm

Overhaul

- Remove the calliper assembling bolts and take out the internal bodies and components. If necessary, in order to make it easier to take out the plungers, inject (shorts blasts of) compressed air through the brake fluid pipe.

- Check that the cylinders of the internal and external body of the calliper do not show scratches or signs of erosion; otherwise, replace the entire calliper.

CAUTION

ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS

SERVICED.

Fit to the calliper body:

- the sealing rings (1-2);

- the plungers (3);

BRAK SYS - 109

Braking system

Vespa LXV 50

- bed the O-Ring gasket (4) on a calliper body.

- Couple the internal body with the external one with assembling bolts. Refitting the pads and purging air (see previous sections).

- Place the calliper on the disc and lock it to the support by tightening the bolts.

-Lock the pipe joint to the calliper at the prescribed torque.

Upon fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc.. They should be washed thoroughly in denatured alcohol before proceeding.

The sealing rings must be immersed in the operating liquid; the use of the PRF1 protection is tolerated.

CAUTION

RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS.

AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A

CLEAN CLOTH.


Screw tightening calliper to the support 20 ÷ 25 Attachment to the calliper 25 ÷ 30 Nm

1 DUST GUARDS

2 SEALING RINGS

3 PLUNGERS

4 O-RING GASKET

Front brake disc

Removal

- Should the brake disc be replaced, when refitting the hub, apply recommended product on the fixing bolts.

Tighten to the specified torque.

N.B.

THE SURFACE OF THE DISC WITH THE STAMPED AR-

ROW INDICATING THE DIRECTION OF ROTATION MUST

FACE THE SHOCK ABSORBER.


Loctite 242 product description

Apply LOCTITE medium type 242 threadlock


BRAK SYS - 110

Vespa LXV 50 tightening torque

5 ÷ 6.5 Nm

Disc Inspection



Characteristic

Max oscillation allowed

0.1 mm.

Front brake pads

Removal

- Pads must be replaced when the friction material thickness reaches the wear limit.

- To replace: remove the protection cover, the bolt and the leaf spring. Slide off the pads and replace them once the plungers are down. Carry out these operations in reverse order to fit.

CAUTION

BEFORE USING THE BRAKE, OPERATE THE LEVER A

FEW TIMES.

Front

-Once the bleed valve is closed, fill the system with brake liquid to the maximum level.

-Undo the bleed screw.

-Apply the tube of the special tool to the bleed screws.

When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system.

Braking system

BRAK SYS - 111

Braking system

The operation is finished when just oil comes out of the bleed screws.

-Do up the bleed screw.

-When the operation is over, tighten up the oil bleed screw to the prescribed torque.

N.B.

IF AIR CONTINUES TO COME OUT DURING PURGING, EX-

AMINE ALL THE FITTINGS:

IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-

TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS

SEALS ON THE PUMP AND CALLIPER PISTONS.

CAUTION

- DURING THE OPERATIONS, THE VEHICLE MUST BE ON

THE STAND AND LEVEL.

N.B.

DURING PURGING FREQUENTLY CHECK THE LEVEL TO

PREVENT AIR GETTING INTO THE SYSTEM THROUGH

THE PUMP.

WARNING

- BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT AB-

SORBS HUMIDITY FROM THE SURROUNDING AIR.

IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EX-

CEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE

REDUCED.

THEREFORE, ALWAYS USE FLUID FROM SEALED CON-

TAINERS.

UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS

YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.

IF THE BRAKES ARE USED INTENSELY AND/OR IN

HARSH CONDITIONS, CHANGE THE FLUID MORE FRE-

QUENTLY.

CAUTION

WHEN CARRYING OUT THE OPERATION, BRAKE FLUID

MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS

SEAT ON THE CALLIPER.

CAREFULLY DRY THE CALLIPER AND DEGREASE THE

DISC SHOULD THERE BE OIL ON IT.


020329Y MityVac vacuum-operated pump


AGIP BRAKE 4 Brake fluid



Oil bleed screw

7 ÷ 10

Front brake pump

BRAK SYS - 112

Vespa LXV 50

Vespa LXV 50

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.


020325Y Brake-shoe spring calliper

Braking system

BRAK SYS - 113

INDEX OF TOPICS

C

HASSIS

CHAS

Vespa LXV 50

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.

Chassis

CHAS - 115

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

Vespa LXV 50

CHAS - 116

Vespa LXV 50

Headlight assy.

- Remove the four fixing screws from the light support.

Knee-guard

- 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.

Chassis

CHAS - 117

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

Vespa LXV 50

CHAS - 118

Vespa LXV 50

Front mudguard

- First remove the steering tube and uncouple the front brake pipes from the calliper in order to remove the front mudguard

- Remove the three mudguard-steering tube clamps indicated in the figure

Front central cover

- Remove the "PIAGGIO" clip-on badge

- Unscrew the screw indicated in the figure

- Remove the grille

Chassis

CHAS - 119

INDEX OF TOPICS

P

RE

-

DELIVERY

PRE DE

Vespa LXV 50

Pre-delivery

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:

- 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 - 121

Pre-delivery

Vespa LXV 50

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 NEG-

ATIVE LEAD.

WARNING

BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-

PHURIC 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 EN-

SURE 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 braking system fluid level.

- Rear hub oil level

- Engine coolant 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 - 122

Vespa LXV 50

Pre-delivery

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 - 123

INDEX OF TOPICS

T

IME

TIME

Vespa LXV 50

This section is devoted to the time necessary to carry out repairs.

The description and code for each operation is indicated.

Engine

Time

1

Code

001001

ENGINE

Action

engine from frame - removal and refitting

Duration

TIME - 125

Time

Crankcase

Vespa LXV 50

1

Code

001133

CRANKCASE

Action

Engine crankcase - Replacement

Duration

TIME - 126

Vespa LXV 50

Crankshaft

Time

3

4

1

2

Code

001118

001100

001099

001117

C

RANKSHAFT

Action

Main bearings - Replacement

Oil seal, clutch side - Replacement

Oil seal, flywheel side - Replacement

Crankshaft - Replacement

Duration

TIME - 127

Time

Cylinder assy.

Vespa LXV 50

1

2

Code

001002

001107

CYLINDER- PISTON

Action

Cylinder-Piston - Replacement

Cylinder / piston - Inspection / cleaning

Duration

TIME - 128

Vespa LXV 50

Cylinder head assy.

Time

3

4

1

2

5

Code

001097

001093

001126

001013

001178

HEAD

Action

Cooling hood - Replacement

Spark plug - Replacement

Head - Replacement

Intake manifold - Replacement

Disc pack - Replacement

Duration

TIME - 129

Time

Driven pulley

Vespa LXV 50

3

4

1

2

Code

001012

001110

001022

001155

DRIVEN PULLEY - CLUTCH

Action

Driven pulley - Service

Driven pulley - Replacement

Clutch - Replacement

Clutch bell housing - Replacement

Duration

TIME - 130

Vespa LXV 50

Oil pump

Time

1

2

3

Code

001028

001019

001018

OIL PUMP

Action

Mix movement gear socket - Replacement


Mixer - Replacement

Duration

TIME - 131

Time

Final gear assy.

Vespa LXV 50

3

4

1

2

Code

001010

001156

003065

004125

F

INAL REDUCTION GEAR

Action

Geared reduction unit - Service

Gear reduction unit cover - Replacement

Gear box oil - Replacement

Rear wheel axle - Replacement

Duration

TIME - 132

Vespa LXV 50

Driving pulley

Time

3

4

1

2

Code

001066

001086

001011

001177

DRIVING PULLEY

Action

Driving pulley - Removal and refitting

Driving half-pulley - replace

Driving belt - Replacement

Variator rollers / shoes - Replacement

Duration

TIME - 133

Time

Transmission cover

Vespa LXV 50

1

2

Code

001096

001135

TRANSMISSION COVER

Action

Transmission crankcase cover - Replacement

Transmission cover bearing - Replacement

Duration

TIME - 134

Vespa LXV 50

Starter motor

Time

3

4

5

6

1

2

Code

001020

005045

001017

001021

008008

001084

ELECTRICAL START-UP

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 - 135

Time

Flywheel magneto

Vespa LXV 50

3

4

1

2

5

Code

001109

001173

001067

001058

001087

MAGNETO FLYWHEEL

Action

Cooling fan - Replacement

Rotor - Replacement

Stator - Fitting and Refitting

Flywheel - Replacement

Flywheel cover - Replacement

Duration

TIME - 136

Vespa LXV 50

Carburettor

Time

6

7

4

5

1

2

3

Code

001008

001063

007020

001081

001082

003058

004177

CARBURETTOR

Action

Carburettor - Inspection

Carburettor - Replacement

Carburettor heating tubing - replacement

Automatic choke - Replacement

Carburettor heating resistor - Replacement

Carburettor - Adjustment

Heating hood - Replacement

Duration

TIME - 137

Time

Exhaust pipe

Vespa LXV 50

1

2

Code

001009

001095

MUFFLER

Action

Muffler - Replacement

Muffler guard - Replacement

Duration

TIME - 138

Vespa LXV 50

Air cleaner

Time

1

2

3

Code

004122

001014

001015

AIR CLEANER

Action

Air cleaner carburettor fitting - Replacement

Air filter - Replacement / cleaning

Air filter box - Replacement

Duration

TIME - 139

Time

Frame

Vespa LXV 50

3

4

1

2

5

6

Code

004001

004023

004149

004159

004012

004059

F

RAME

Action

Chassis - Replacement

Shield rim - Replacement

Shield central cover - Replacement

Plates / Stickers - Replacement

Rear side panels - Replacement

Spark plug inspection flap - Replacement

Duration

TIME - 140

Vespa LXV 50

Centre-stand

1

2

Code

004004

004171

STAND

Action

Stand - Replacement

Stand support plate - Replacement

Duration

Time

TIME - 141

Time

Footrests

Vespa LXV 50

1

2

Code

004078

004178

F

OOTREST

Action

Front/rear footrest rubber - Replacement

Footrest - Replacement

Duration

TIME - 142

Vespa LXV 50

Rear cover

Time

3

4

1

2

Code

004174

004065

004081

004082

S

HIELD BACK PLATE

Action

Trunk levers - Replacement

Front shield, rear part - Removal and refitting

Glove box door - Replacement

Trunk gasket - Replacement

Duration

TIME - 143

Time

Underseat compartment

Vespa LXV 50

3

4

1

2

Code

004016

005046

004011

004071

HELMET COMPARTMENT

Action

Helmet compartment - Replacement

Battery cover - change

Central chassis cover - Replacement

Battery compartment - replacement

Duration

TIME - 144

Vespa LXV 50

Plate holder

Time

1

2

3

Code

004136

005048

005032

LICENSE PLATE HOLDER

Action

License plate support - Replacement

Licence plate holder - Replacement

Licence plate light glass - Replacement

Duration

TIME - 145

Time

Mudguard

Vespa LXV 50

1

2

Code

004002

004009

MUDGUARDS

Action

Front mudguard - Replacement

Rear mudguard - Replacement

Duration

TIME - 146

Vespa LXV 50

Fuel tank

Time

4

5

6

1

2

3

Code

004168

005010

004112

004005

004007

004109

FUEL TANK

Action

Fuel tank cap - Replacement

Tank float - Replacement

Cock-carburettor hose - Replacement

Fuel tank - Replacement

Fuel valve - Replacement

Fuel tank breather - Replacement

Duration

TIME - 147

Time

Tank oil

Vespa LXV 50

3

4

1

2

Code

005018

004017

004095

004091

Rear shock-absorber

OIL RESERVOIR

Action

Oil reservoir float - Replacement

Oil reservoir - Replacement

Oil reservoir cock - Replacement

Oil reservoir hose - Replacement

Duration

TIME - 148

Vespa LXV 50

1

Code

003007

Steering column bearings

REAR SHOCK ABSORBER

Action

Rear shock absorber - Removal and

Refitting

Duration

Time

1

2

3

Code

003002

003073

004119

S

TEERING FIFTH WHEELS

Action

Steering fifth wheel - Replacement

Steering clearance - Adjustment

Bearing / upper steering fifth wheel -

Replacement

Duration

TIME - 149

Time

Handlebar covers

Vespa LXV 50

3

4

5

1

2

Code

004053

004018

005014

005038

004019

ODOMETER - HANDLEBAR COVERS

Action

Spoiler - Replacement

Handlebar front section - Replacement

Odometer - Replacement

Instrument panel warning light bulbs

- Replacement

Handlebar rear section - Replacement

Duration

TIME - 150

Vespa LXV 50

Handlebar components

Time

7

8

9

3

4

1

2

5

6

10

Code

004066

002037

002071

003001

005017

002024

002054

002060

004162

002059

HANDLEBAR COMPONENTS

Action

Driving mirror - Replacement

Brake or clutch lever - Replacement

Left hand grip - Replacement

Handlebar - Replacement

Stop switch - Replacement

Front brake pump - Removal and Refitting

Throttle or splitter transmission complete - Replacement

Complete throttle control - Replacement

Mirror support and/or brake pump fitting U-bolt - Replacement

Right hand grip - Replacement

Duration

TIME - 151

Time

Swing-arm

Vespa LXV 50

1

Code

001072

SWINGING ARM

Action

Swinging arm - Engine-chassis connection - Replacement

Duration

TIME - 152

Vespa LXV 50

Seat

1

2

Code

004003

004008

SADDLE

Action

Saddle - Replacement

Luggage rack - Replacement

Duration

Time

TIME - 153

Time

Turn signal lights

Vespa LXV 50

6

7

4

5

8

1

2

3

Code

005002

005012

005067

005008

005005

005066

005022

005068

TURN INDICATOR LIGHTS

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 - 154

Vespa LXV 50

Front wheel

Time

3

4

1

2

5

6

Rear wheel

Code

004123

003047

003037

003033

002041

003034

FRONT WHEEL

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

TIME - 155

Time

3

4

1

2

Electric devices

Code

004126

001071

001016

002002

Vespa LXV 50

REAR WHEEL

Action

Rear wheel tyre - Replacement

Rear wheel rim - Removal and Refitting

Rear wheel - Replacement

Rear brake pads/shoes - Replacement

Duration

5

6

3

4

7

8

1

2

TIME - 156

Code

005001

005011

005009

005007

005052

001023

001094

005054

E

LECTRICAL COMPONENTS

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

Fuse block (1) - Replacement

Duration

Vespa LXV 50

Electronic controls

Time

5

6

3

4

7

8

1

2

Code

005039

005006

005040

005003

005041

005016

004096

004010

ELECTRICAL CONTROLS

Action

Headlight switch - Replacement

Light switch or turn indicators - Replacement

Horn button - Replacement

Horn - Replacement

Starter button - Replacement

Key switch - Replacement

Lock series - Replacement

Anti-theft lock - Replacement

Duration

TIME - 157

Time

Transmissions

Vespa LXV 50

1

4

5

2

3

6

7

Code

002051

002012

002057

002058

002053

002049

003061

T

RANSMISSION

Action

Odometer transmission assembly -

Replacement

Splitter - Replacement

Carburettor / splitter transmission complete - Replacement

Mix / splitter transmission complete -

Replacement

Rear brake transmission complete -

Replacement

Odometer cable - Replacement

Accelerator transmission - Adjustment

Duration

TIME - 158

Vespa LXV 50

Brake callipers

Time

1

2

3

4

Code

002021

002007

002039

002047

CALLIPER

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

Duration

TIME - 159

Time

Front suspension

Vespa LXV 50

4

5

6

1

2

3

Code

003045

003010

003035

001064

003044

003038

FRONT SUSPENSION

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

TIME - 160

Vespa LXV 50

Secondary air box

Time

1

2

3

4

5

Code

001164

001161

001162

001163

001165

SECONDARY AIR HOUSING

Action

Crankcase secondary air connection

- Replacement

Secondary air filter - Replacement /

Cleaning

Secondary air housing - Replacement

Muffler secondary air connection -

Replacement

Secondary air reed - Replacement

Duration

TIME - 161

A

Air filter: 32, 118

B

Battery: 40, 47, 55

Brake: 109–113, 159

C

Carburettor: 11, 29, 137

E

Engine stop:

F

Fuel: 39, 90, 147

Fuses: 54

H

Headlight: 35, 117

Hub oil: 31

I

Identification: 8

Instrument panel: 116

M

Maintenance: 7, 27

O

Odometer:

S

Saddle:

Shock absorbers: 106

Spark plug: 30

Stand:

Start-up:

T

Tank: 147, 148

Transmission: 9, 39, 62, 134

Tyres: 10

VESPA LXV 50 Service Station Manual

Assistant Bot

SERVICE STATION MANUAL

SERVICE STATION

MANUAL

SERVICE STATION MANUAL

Rules

Safety rules

Maintenance rules

Vehicle identification

Dimensions and mass

Engine

Transmission

Capacities

Electrical system

Frame and suspensions

Brakes

Wheels and tyres

Secondary air

Carburettor

50cc Version

Dell'Orto

Tightening Torques

Overhaul data

Assembly clearances

Cylinder - piston assy.

Piston rings

Crankcase - crankshaft - connecting rod

Slot packing system

Products

Maintenance chart

Carburettor

Checking the spark advance

Spark plug

Hub oil

Check

Replacement

Air filter

Checking the ignition timing

Braking system

Level check

Top-up

Headlight adjustment

SAS filters inspection and cleaning

Engine

Poor performance

Rear wheel spins at idle

Starting difficulties

Excessive oil consumption/Exhaust smoke

Engine tends to cut-off at full throttle

Engine tends to cut-off at idle

Excessive exhaust noise

High fuel consumption

SAS malfunctions

Transmission and brakes

Clutch grabbing or performing inadequately

Insufficient braking

Brakes overheating

Electrical system

Battery

Steering and suspensions

Heavy steering

Excessive steering play

Noisy suspension

Suspension oil leakage

Conceptual diagrams

Ignition

Headlights and automatic starter section

Battery recharge and starting

Level indicators and enable signals section

Devices and accessories

Checks and inspections

Ignition circuit

Voltage regulator check

Fuses

Sealed battery

Dry-charge battery

Removal of the engine from the vehicle

Automatic transmission

Transmission cover