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Vespa LXV 125 User Manual

Vespa LXV 125
226 pages
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Service station manual
633852 IT - 633853 EN - 633854 FR - 633855 DE -
633856 ES - 633857 PT - 633858 NL - 633859 EL
LXV 125

Table of Contents

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Vespa LXV 125 Specifications

General IconGeneral
Engine TypeSingle-cylinder, 4-stroke
Displacement124 cc
Cooling SystemAir-cooled
Fuel SystemCarburetor
Seat Height785 mm
Max Torque9.6 Nm at 6, 000 rpm
Length1, 770 mm
Front Brake200 mm disc brake
Rear Brake110 mm drum brake
Weight114 kg
Top Speed91 km/h
TransmissionAutomatic CVT
Rear SuspensionCoil spring and hydraulic shock absorber

Summary

Vespa LXV 125 Service Station Manual

Rules and Safety

General safety rules for maintenance operations on the vehicle, covering rules for work, battery, and fuel.

Vehicle Characteristics and Specifications

Engine Specifications

Technical data for the engine, including bore, stroke, cubic capacity, and cooling.

Transmission System

Details about the transmission system, including variator, V belt, and cooling.

Brakes Specifications

Specifications for front and rear brakes, including disc and drum types.

Carburettor Settings

Carburettor settings and specifications for the CVEK26 model.

Assembly Clearances

Details on assembly clearances for cylinder-piston assembly.

Cylinder-Piston Assembly Clearances

Piston ring specifications for dimensions and clearances.

Crankcase-Crankshaft Clearances

Axial clearance specifications between crankshaft and connecting rod.

Crankshaft-Half-Bearing Clearances

Axial clearance specifications between crankshaft and its half-bearings.

Specialized Tools for Vespa LXV 125

Appropriate Tools List

List of specific tools required for vehicle maintenance and repair, with their codes.

Scheduled Maintenance and Inspections

Vehicle Maintenance Chart

Scheduled maintenance tasks based on time intervals or mileage for the vehicle.

Troubleshooting Common Issues

Engine Performance Problems

Diagnosing and resolving issues related to poor engine performance.

Starting Difficulties

Troubleshooting common starting difficulties, such as battery issues or flooded engines.

Low Lubrication Pressure

Troubleshooting steps for low oil pressure, including checking the by-pass and oil filter.

Clutch Grabbing or Slipping

Diagnosing clutch issues like grabbing or slippage, and checking clutch masses.

Insufficient or Noisy Braking

Troubleshooting inefficient or noisy braking, including pad wear and fluid leaks.

Brakes Overheating

Identifying causes of brake overheating, such as stuck gaskets or clogged pump holes.

Battery Troubleshooting

Troubleshooting battery-related issues, including charging and maintenance.

Heavy Steering Diagnosis

Diagnosing and resolving heavy steering issues, checking bearing seats and ring nuts.

Excessive Steering Play

Troubleshooting excessive steering play, focusing on ring nut tightening and bearing wear.

Electrical System Schematics and Checks

Ignition System Diagram

Schematic and component legend for the ignition system.

Immobilizer System

Description and checks of the immobilizer system components and diagnostic codes.

Immobilizer Diagnostic Codes

Explanation of diagnostic codes and LED indicators for the immobilizer system.

Ignition Circuit Procedures

Procedures and precautions for operations on the ignition circuit.

No Spark Plug Troubleshooting

Troubleshooting steps when there is no spark at the spark plug.

Engine Removal and Components

Engine Removal from Vehicle

Step-by-step guide for removing the entire engine from the vehicle's chassis.

Engine Component Service

Crankcase Halves Refitting

Steps for refitting crankcase halves, including bulkhead, oil filter joint, and gasket.

Crankcase Splitting Procedure

Procedure for splitting the crankcase halves and removing the crankshaft.

Connecting Rod Clearances

Checking the axial clearance on the connecting rod.

Radial Clearance Checks

Checking the radial clearance on the connecting rod and crankshaft surfaces.

Crankshaft Bearing Diameter Checks

Checking crankshaft bearing diameters and classification into categories.

Crankshaft Alignment Inspection

Procedure for inspecting crankshaft alignment using a support and dial gauge.

Crankcase Halves Inspection

Cleaning and inspecting crankcase halves, oil ducts, and mating surfaces.

Crankshaft Plain Bearings Inspection

Checking crankshaft plain bearings for lubrication, position, and driving depth.

Oil Pressure Check

Procedure for checking engine oil pressure at different RPMs and temperatures.

Oil Pump System

Steps for removing, inspecting, and refitting the oil pump.

Oil Sump Removal and Inspection

Steps for removing the oil sump and inspecting the by-pass valve.

SAS Valve Inspection

Procedure for inspecting the SAS valve's one-way function using a vacuum pump.

Cut-off Valve Inspection

Procedure for inspecting the cut-off valve's vacuum operation and seal integrity.

Fuel Supply System Testing

Procedure for checking fuel supply and flow rate using a vacuum pump and burette.

Carburettor Removal and Refitting

Steps for removing and refitting the carburettor, including cleaning and adjustment.

Automatic Choke Device Inspection

Checking the automatic choke piston, gasket, protrusion, and resistance.

Idle Speed Adjustment

Procedure for adjusting the engine idle speed, including temperature and RPM checks.

Suspension System Service

Front Suspension Components

Operations related to the front suspension system.

Steering Column Service

Procedures for removing, overhauling, and refitting the steering column.

Steering Bearing Service

Procedure for removing and refitting steering bearings, including seats and fifth wheel fittings.

Braking System Components

Brake Disc Inspection

Procedure for inspecting the brake disc thickness and deviation using a micrometer.

Rear Drum Brake Service

Steps for removing and refitting brake shoes and springs for the rear drum brake.

Pre-Delivery Inspection and Checks

Road Test Procedure

Items to check during a road test, including starting, controls, and performance.

Time Estimates for Service Operations

Oil Pump System Time

Time allocation for belt/chain, chain pads, oil pump service/change, and oil sump replacement.

Starting System Time Estimates

Time allocation for starter motor, cable harness, sprocket wheel, and kick starter replacement.

Flywheel Magneto Time Estimates

Time allocation for cooling fan, rotor, stator, and flywheel replacement.

Carburettor Service Time

Time allocation for carburettor resistor, manifold, fitting, choke, and carburettor replacement.

Handlebar Components Time

Time allocation for mirrors, levers, grips, handlebar, switches, brake pump, and throttle control replacement.

Electronic Controls Time

Time allocation for headlight switch, turn indicators, horn, starter button, key switch, and locks replacement.

Braking System Components Time

Time allocation for brake hose, shoes/pads, caliper, fluid bleeding system, and rear brake pads replacement.

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