Vespa LXV 125 I.E. (EN)

SERVICE STATION MANUAL
665333 IT-665334 EN-665335 FR-665336 DE-665337 ES-665339 PT-665340 NL
Vespa LXV 125 i.e.
Vespa LXV 125 i.e.
The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. 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 each model should be checked at the official PIAGGIO sales network. Copyright 2013 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy www.piaggio.com

Vespa LXV 125 i.e.
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE INJECTION SUSPENSIONS BRAKING SYSTEM CHASSIS PRE-DELIVERY
CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG INJEC SUSP BRAK SYS CHAS PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Vespa LXV 125 i.e.
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 well ventilated, 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. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Characteristics
Vespa LXV 125 i.e.
Vehicle identification
VEHICLE IDENTIFICATION
vehicle identification
Specification Chassis prefix Engine prefix Desc./Quantity ZAPM4430000 to 100001 M444Mto 1001
Dimensions and mass
WEIGHTS AND DIMENSIONS

Specification Kerb weight Maximum height Width Wheelbase Length Desc./Quantity 118 6 kg 1225 mm 740 mm 1280 mm 1770 mm
CHAR - 8
Vespa LXV 125 i.e.
Characteristics
Engine
ENGINE
Specification ENGINE Timing system Valve clearance Bore x stroke Engine capacity Compression ratio Engine idle speed Air filter Fuel system Starting system Lubrication Minimum lubrication pressure (100 C) Lubrication pressure Max. power MAX. torque Cooling Desc./Quantity Single cylinder 4-stroke Single overhead camshaft (SOHC) with 2 valves intake 0.10 exhaust 0.15 57 x 48.6 mm 124 cm 10.6 0.5 to 1 1,750 50 rpm sponge, impregnated with mixture (50% petrol and 50% oil) Electronic injection with electric fuel pump. electric starter motor with freewheel with lobe pump (inside the crankcase) chain-driven and double filter: mesh and paper 0.8 bar 3.5 to 4 bar 7.9 kW at 8250 rpm 9.6 Nm at 6500 rpm Forced-circulation air cooling.
Transmission
TRANSMISSION
Specification Transmission
Final reduction gear
Desc./Quantity With continuously variable expandable pulley transmission with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling. Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification Engine oil Rear hub oil Fuel tank capacity Desc./Quantity 1100 cc (67.13 cu.in) ~ 100 cm 8.2 litres (2 l of them for reserve)
Electrical system
ELECTRICAL COMPONENTS
Specification Spark plug Battery Fuses Alternator Ignition/advance Desc./Quantity NGK CR8EB or DENSO U24ESR-NB 12V - 10 Ah Sealed battery 1 of 20A - 1 of 15A - 4 of 7.5A alternating current Electronic with inductive discharge and variable advance
CHAR - 9
Characteristics
Vespa LXV 125 i.e.
CHECKING RELAYS A OPERATING AS CIRCUIT BREAKERS 1) Check that, given regular conditions, there is no continuity between terminals 30 and 87. 2) Apply 12V voltage to power terminals 85 and 86 of the relay. 3) With the relay powered, check that there is continuity between terminals 30 and 87. 4) If these conditions are not fulfilled, the relay is damaged and must be replaced. To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts. TURN INDICATOR SWITCH
HORN BUTTON
LIGHT SWITCH
CHAR - 10
Vespa LXV 125 i.e.
Characteristics
ENGINE STOP SWITCH
STARTER BUTTON
IGNITION SWITCH
FUEL INJECTOR Type: 3 holes Conicity of the nozzle: 20 Resistance at terminals: 13.7 - 15.2 Ohm
CHAR - 11
Characteristics
Vespa LXV 125 i.e.
FUEL PUMP UNIT Mechanical type pressure regulator operating at a pressure of 2.5 BAR Pump winding resistance: ~ 1.5 Ohm Input current during regular functioning: 1.4 - 1.8 A
SPEED/PHASE SENSOR Resistance at the component ends: 100 to 150 Ohm at approx. 20
ENGINE TEMPERATURE SENSOR 0 = 9440 Ohm +10 = 5660 Ohm +20 = 3500 Ohm +30 = 2265 Ohm +80 = 357 Ohm
MINIMUM OIL PRESSURE SENSOR Normally closed switch Activation threshold: 0.3 - 0.6 BAR With the engine off: continuity between muffler and ground
HV COIL <DIV class=O v:shape="_x0000_s3074"> - Resistance of the primary = 0.5 Ohm 8% - Resistance between primary and ground = infinite - Resistance between primary and H.V. output = 3.1KOhm 9% CHAR - 12
Vespa LXV 125 i.e.
Characteristics
- Presence of battery voltage at component ends when key is ON and for 2 sec
STATOR Power: 450 W Resistance between terminals: 0.2 - 1 Ohm terminal insulation from ground
Frame and suspensions

CHASSIS AND SUSPENSION
Specification Chassis Front suspension Front suspension travel Rear suspension Rear suspension travel Desc./Quantity Stamped plate body with welded structural reinforcements. Single arm with helical spring and single double-acting hydraulic shock absorber. 70.3 mm Double-acting shock absorber, adjustable to four positions at preloading. 83 mm
Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity 200-mm disc brake with hydraulic control activated by handlebar right-side lever. 110-mm drum brake with mechanical control activated by handlebar left-side lever.
Wheels and tyres

WHEELS AND TYRES
Specification Front wheel rim Front tyre Desc./Quantity Die-cast aluminium alloy; 2.50 x11" Tubeless, 110/70-11'' 45L
CHAR - 13
Characteristics
Vespa LXV 125 i.e.
Specification Rear wheel rim Rear tyre Front tyre pressure Rear tyre pressure Rear wheel pressure (rider and passenger): N.B.
Desc./Quantity Die-cast aluminium alloy; 3.00 x 10" Tubeless, 120/70-10'' 54L 1.6 bar 2 bar 2.3 bar
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES
Tightening Torques
LUBRICATION
Name Hub oil drainage cap Minimum oil pressure sensor Oil filter Oil pump cover screws Screws fixing oil pump to the crankcase Oil pump command sprocket screws Chain cover screws Oil sump screws Minimum oil pressure sensor Blow-by recovery duct fixing screws Engine oil drainage plug / mesh filter Torque in Nm 15 to 17 12 to 14 4 to 6 5 to 6 5 to 6 10 to 14 4 to 6 10 to 14 12 to 14 3-4 24 to 30
MUFFLER
Name Silencer heat guard fixing screw Screws fixing silencer to the crankcase Lambda probe tightening on exhaust manifold Torque in Nm 4 to 5 24 27 40 to 50
HEAD AND CYLINDER

Name Ignition spark plug Head cover screws Nuts fixing head to cylinder (*) Head fixing screws (external) Starter ground screw Flywheel cover screw Flywheel air duct screw Pressure reducer counterweight retainer Camshaft sprocket screw Timing chain tensioner slider screw Starter counterweight support screw Tensioner screws Timing chain tensioner central screw Camshaft retention plate screw Nut fixing silencer to cylinder head Head intake manifold screw Torque in Nm 12 to 14 11 - 13 28 to 30 11 to 13 7 to 8.5 1 to 2 3-4 7 - 8.5 12 to 14 10 to 14 11 to 15 11 to 13 5-6 4 to 6 16 to 18 11 to 13
(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.
TRANSMISSION
Name Drive pulley nut Transmission cover screw Driven pulley shaft nut Rear hub cap screw Clutch unit nut on driven pulley Hub oil drainage screw Torque in Nm 75 - 83 11 to 13 54 - 60 24 to 27 45 to 50 15 to 17
CHAR - 14
Vespa LXV 125 i.e.
Characteristics
FLYWHEEL
Name Flywheel fan screws Stator assembly screws () Flywheel nut Pick-up screw () Apply LOCTITE 242 threadlock Torque in Nm 3 to 4 3 to 4 52 - 58 3 to 4
CRANKCASE AND CRANKSHAFT

Name Internal engine crankcase bulkhead (transmission-side half shaft) screws Oil filter on crankcase fitting Rear brake cam tightening screw Engine-crankcase coupling screws Pre-filter cap Starter motor fixing screw Torque in Nm 4 to 6 27 - 33 11 to 13 11 13 24 to 30 11 to 13
STEERING ASSEMBLY
Name Steering upper ring nut Steering lower ring nut Handlebar fixing screw Torque in Nm 35 to 40 12 to 14 50 to 55
CHASSIS ASSEMBLY
Name Swinging arm - chassis pin Engine-swinging arm bolt Stand bolt Swinging arm silent-block containment bolt Torque in Nm 44 to 52 33 - 41 32 to 40 33 to 41
FRONT SUSPENSION
Name Shock absorber upper nut Front wheel axle nut Shock absorber upper bracket bolts Wheel screw Shock absorber lower bolts () () Apply LOCTITE 242 threadlock Torque in Nm 20 to 30 75 to 90 20 to 25 20 to 25 20 to 27
FRONT BRAKE
Name Brake fluid pump-hose fitting Brake fluid pipe-calliper fitting Screw tightening calliper to support Brake disc screw () Oil bleed valve (on the calliper) Handlebar pump Brake pump reservoir screw () Apply LOCTITE 242 threadlock Torque in Nm 8 to 12 20 25 20 - 25 5 to 6.5 10 to 12 7 10 15 to 20
REAR SUSPENSION
Name Rear wheel axle Shock absorber lower clamping Shock-absorber/chassis nut Torque in Nm 104 126 33 to 41 20 to 25
CHAR - 15
Characteristics
Vespa LXV 125 i.e.
Overhaul data Assembly clearances Cylinder - piston assy.

COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST-IRON LINER
Name Coupling Coupling Coupling Coupling Coupling 1st oversize Coupling 1st oversize Coupling 1st oversize Coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Initials A B C D A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3 Cylinder 56.980 to 56.987 56.987 to 56.994 56.994 to 57.001 57.001 to 57.008 57.180 to 57.187 57.187 to 57.194 57.194 to 57.201 57.201 to 57.208 57.380 to 57.387 57.387 to 57.394 57.394 to 57.401 57.401 to 57.408 57.580 to 57.587 57.587 to 57.594 57.594 to 57.601 57.601 to 57.608 Piston 56.933 to 56.940 56.940 to 56.947 56.947 to 56.954 56.954 to 56.961 57.133 to 57.140 57.140 to 57.147 57.147 to 57.154 57.154 to 57.161 57.333 to 57.340 57.340 to 57.347 57.347 to 57.354 57.354 to 57.361 57.533 to 57.540 57.540 to 57.547 57.547 to 57.554 57.554 to 57.561 Play on fitting 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054
PISTON TO CAST IRON CYLINDER COUPLING

Name Coupling Coupling Coupling Coupling coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Initials M N O P M1 N1 O1 P1 M2 N2 O2 P2 M3 N3 O3 P3 Cylinder 56.997 - 57.004 57.004 - 57.011 57.011 - 57.018 57.018 - 57.025 57.197 - 57.204 57.204 - 57.211 57.211 - 57.218 57.218 - 57.225 57.397 - 57.404 57.404 - 57.411 57.411 - 57.418 57.418 - 57.425 57.597 - 57.604 57.604 - 57.611 57.611 - 57.618 57.618 - 57.625 Piston 56.944 - 56.951 56.951 - 56.958 56.958 - 56.965 56.965 - 56.972 57.144 - 57.151 57.151 - 57.158 57.158 - 57.165 57.165 - 57.172 57.344 - 57.351 57.351 - 57.358 57.358 - 57.365 57.365 - 57.372 57.544 - 57.551 57.551 - 57.558 57.558 - 57.565 57.565 - 57.572 Play on fitting 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060
Piston rings
SEALING RINGS
Name Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st oversize Oil scraper ring 1st oversize Description Dimensions 57 x 1 57x1 57x2.5 57.2 x 1 57.2x1 57.2x2.5 Initials A A A A A A Quantity 0.15 - 0.30 0.10 - 0.30 0.10 - 0.35 0.15 - 0.30 0.10 - 0.30 0.10 - 0.35
CHAR - 16
Vespa LXV 125 i.e.
Characteristics
Name Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize
Description
Dimensions 57.4x1 57.4x1 57.4x2.5 57.6x1 57.6x1 57.6x2.5
Initials A A A A A A
Quantity 0.15 - 0.30 0.10 - 0.30 0.10 - 0.35 0.15 - 0.30 0.10 - 0.30 0.10 - 0.35
Maximum clearance after use: 1 mm
Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Half-shaft, transmission side Flywheel-side half shaft Connecting rod with PP Crank pin width Description Dimensions 16.6 +0-0.05 16.6 +0-0.05 18 -0.10 -0.15 51.400 Initials A B C E Quantity D = 0.20 - 0.50 D = 0.20 - 0.50 0.20 to 0.50
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

Name Crankshaft Crankshaft Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1 Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2 Description Dimensions Initials Category 1 Category 2 Category 1 Category 2 Category B - blue Category C - yellow Category E - green E-E C-C C-C B-B Quantity 28.998 - 29.004 29.004 - 29.010 32.953 - 32.959 32.959 - 32.965 1.973 - 1.976 1.976 - 1.979 1.979 - 1.982
Crankshaft/crankcase axial clearance: 0.15 to 0.40
CHAR - 17
Characteristics
Vespa LXV 125 i.e.
Slot packing system

- Provisionally fit the piston into the cylinder, without any base gasket. - Assemble a dial gauge on the specific tool - Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure. - Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation) - Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio. - Remove the special tool and the cylinder.
Characteristic
Compression ratio 10.6 0.5 to 1
SHIMMING SYSTEM
Specification Value measured Thickness Value measured Thickness Value measured Thickness Desc./Quantity 0 - 0.1 0.8 0.05 0.1 - 0.3 0.6 0.05 0.3 - 0.4 0.4 0.05
CHAR - 18
Vespa LXV 125 i.e.
Characteristics
Products
RECOMMENDED PRODUCTS TABLE
Product AGIP GEAR SAE 80W-90 AGIP BRAKE 4 Description Lubricant for gearboxes and transmissions. Brake fluid. Specifications API GL-4 Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4 JASO MA, MA2 - API SL - ACEA A3 ISO L-X-BCHA 3 - DIN 51 825 K3K -20 R.I.D./A.D.R. 2 10b) 2 R.I.Na. 2.42 I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Page 9022 EM 25-89
eni i-Ride PG 5W-40 AGIP FILTER OIL AGIP GREASE MU3 AGIP GP 330
Synthetic based lubricant for high-performance four-stroke engines. Special product for the treatment of foam filters. Yellow-brown, lithium-base, medium-fibre multipurpose grease. Water repellent stringy calcium spray grease.
CHAR - 19
INDEX OF TOPICS
TOOLING
TOOL
Vespa LXV 125 i.e.
Tooling
SPECIFIC TOOLS
Stores code 001330Y Description Tool for fitting steering seats
001467Y009
Bell for OD 42-mm bearings
001467Y013
Calliper to extract 15-mm bearings
001467Y014
Calliper to extract 15-mm bearings
001467Y017
Bell for bearings, OD 39 mm
002465Y
Calliper for circlips
TOOL - 21
Tooling
Vespa LXV 125 i.e.
Stores code 005095Y
Description Engine support
006029Y
Punch for fitting steering bearing seat on steering tube
008564Y
Flywheel extractor
020004Y
Punch for removing steering bearings from headstock
020021Y
Front suspension service tool
TOOL - 22
Vespa LXV 125 i.e.
Tooling
Stores code 020036Y
Description Punch
020037Y
Punch
020038Y
Punch
020055Y
Wrench for steering tube ring nut
020074Y
Support base for checking crankshaft alignment
020150Y
Air heater mounting
020151Y
Air heater
TOOL - 23
Tooling
Vespa LXV 125 i.e.
Stores code 020193Y
Description Oil pressure check gauge
020262Y
Crankcase splitting plate
020263Y
Driven pulley assembly sheath
020287Y
Clamp to fit piston on cylinder
020306Y
Punch for assembling valve seal rings
020325Y
Pliers for brake-shoe springs
TOOL - 24
Vespa LXV 125 i.e.
Tooling
Stores code 020329Y
Description Mity-Vac vacuum-operated pump
020330Y
Stroboscopic light to check timing
020331Y
Digital multimeter
020332Y
Digital rpm indicator
020333Y
Single battery charger
TOOL - 25
Tooling
Vespa LXV 125 i.e.
Stores code 020334Y
Description Multiple battery charger
020335Y
Magnetic mounting for dial gauge
020357Y 020359Y
32 x 35-mm Adaptor 42 x 47-mm Adaptor
020360Y
52 x 55-mm Adaptor
020363Y
20-mm guide
TOOL - 26
Vespa LXV 125 i.e.
Tooling
Stores code 020364Y
Description 25-mm guide
020365Y
22 mm guide
020368Y
driving pulley lock wrench
020375Y
28 x 30 mm adaptor
020376Y
Adaptor handle
020382Y 020382Y011
Tool to extract valve cotters adapter for valve removal tool
TOOL - 27
Tooling
Vespa LXV 125 i.e.
Stores code 020412Y
020414Y
28-mm guide
020423Y
Driven pulley lock wrench
020424Y
Driven pulley roller casing fitting punch
020425Y
Punch for flywheel-side oil seal
020426Y
Piston fitting fork
020456Y
24 mm adaptor
TOOL - 28
Vespa LXV 125 i.e.
Tooling
Stores code 020427Y
Description Piston assembly band
020428Y
Piston position check mounting
020430Y
Pin lock fitting tool
020431Y
Valve oil seal extractor
020434Y
Oil pressure check fitting
020441Y
26 x 28 mm adaptor
TOOL - 29
Tooling
Vespa LXV 125 i.e.
Stores code 020439Y
020444Y
Tool for fitting/ removing the driven pulley clutch
020480Y
Petrol pressure check kit
020481Y
Control unit interface wiring
020565Y
Flywheel lock calliper spanner
020622Y
Transmission-side oil seal punch
020922Y
Diagnosis Tool
TOOL - 30
Vespa LXV 125 i.e.
Tooling
TOOL - 31
INDEX OF TOPICS
MAINTENANCE
MAIN
Vespa LXV 125 i.e.
Maintenance
Maintenance chart
MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check level every 3,000 km ** Replace every 2 years Km x 1,000 Safety fasteners Centre stand bracket Drive belt Throttle control Air filter Oil filter Mesh oil filter Valve clearance Electrical system and battery Cylinder ventilation system Brake levers Brake fluid ** Engine oil * Hub oil Headlight direction adjustment Brake pads Sliding shoes / CVT rollers Tyre pressure and wear Vehicle road test Odometer gear Suspension Steering Transmission Operation time 1 I 6 L I A C R C A I 12 I L R A C R C I 18 L I C R C A I 24 I L R A C R C 30 L I C R C I 36 I L R A C R C A I L I R R A I R I I L I A L 270' 42 L I C R C I 48 I L R A C R C 54 L I C R C A I 60 I L R A C R C
C I L I R R I I I
A 80'
I C L L I I I I R R R R I I I R A A I I I I I R I R I I I I I I I I L L I I A A L L 150' 160' 150' 175'
I R I I I I I
I R I I I I I
95'
95'
I I C L L I I I R R R R I I A A I I I R I R I I I I I I L L I I A A L L 175' 150' 160'
Spark plug
- Position the vehicle on the stand - Open the saddle and remove the helmet compartment. - Remove the spark plug external inspection door by undoing the indicated screw
MAIN - 33
Maintenance
Vespa LXV 125 i.e.
- Disconnect spark plug HV cable hood and, acting on the engine compartment, release the cable from the retaining bracket. - Slide the internal cover upwards.
- Unscrew the spark plug using the wrench supplied.
- Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or sooty, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge. -Adjust the distance, if necessary, by bending the side electrode very carefully. In case of anomaly (as described before), replace the spark plug with another of the recommended type.
- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it. - Refit the cover. - Place the cap fully over the spark plug, and tie down the cable to the bracket. - Carry out refit operations.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD.THE SPARK PLUG MUST BE REPLACED EVERY 20,000 KM. THE USE OF NON CONFORMING ELECTRONIC IGNITION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE. MAIN - 34
Vespa LXV 125 i.e.
Maintenance
Characteristic
Electrode gap 0.7 to 0.8 mm Spark plug NGK CR8EB or DENSO U24ESR-NB
Locking torques (N*m)

Spark plug 12 14
Hub oil Check

- Park the vehicle on flat ground and rest it on the centre stand. - Unscrew the oil dipstick/cover, dry it with a cloth and reinsert it screwing it in thoroughly.
- Remove the dipstick/cover and check that the oil level is between MIN and MAX. - If the level is below the MIN value, restore the proper amount of oil in the hub. - Screw the oil dipstick back and check it is locked.
Replacement
- Remove the oil dipstick/cover.
MAIN - 35
Maintenance
Vespa LXV 125 i.e.
- Remove the rear wheel. - Prepare an adequately sized container. - Unscrew the oil drainage plug and drain out all the oil.
- Screw in the drainage cap again and fill the hub with the prescribed oil.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmissions. API GL-4
Characteristic
Rear hub oil Capacity ~ 100cc

Hub oil drainage screw 15 to 17 Nm
Air filter
Proceed as follows: - Undo the indicated fixing screws. - Remove the left side fairing.
- Remove the helmet compartment. - Undo the six screws and remove the air-box cover. - Remove the filtering element and clean it with water and shampoo; then dry it with a clean cloth and short blasts of compressed air. Finally, immerse it in a mixture of 50% oil of the recommended type and 50% petrol. Then gently squeeze the
MAIN - 36
Vespa LXV 125 i.e.
Maintenance
filter element between your hands, allow it to drip and then refit it. Possible oil or water deposits can be eliminated by removing the rubber lower cap.
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
AGIP FILTER OIL Special product for the treatment of foam filters. -
Engine oil
In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Replacement
Change oil and replace filter as indicated in the scheduled maintenance table. The engine must be emptied by draining off the oil through the drainage plug of the mesh pre-filter, flywheel side; furthermore to facilitate oil drainage, loosen or remove the cap/dipstick. Once all the oil has drained through the drainage hole, unscrew the oil cartridge filter and remove it. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
MAIN - 37
Maintenance
Vespa LXV 125 i.e.
Since a certain quantity of oil still remains in the circuit, oil must be filled from oil dipstick/cover. Then start up the vehicle, leave it running for a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.
N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
Check
This operation must be carried out with the engine cold and following the procedure below: - Place the vehicle on its centre stand and on flat ground. - Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely. - Remove the cap/dipstick again and check that the level is between the MIN and MAX reference marks; top up if necessary. The MAX level mark indicates a quantity of around 1100 cc of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level. Engine oil top-up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 200 cc.
MAIN - 38
Vespa LXV 125 i.e.
Maintenance
Engine oil filter

Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3
Oil pressure warning light

The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the ON position. However, this light should switch off once the engine has started. If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.
MAIN - 39
Maintenance
Vespa LXV 125 i.e.
Checking the ignition timing

-Remove the flywheel fan. -Rotate the flywheel until the reference (arrow) matches the crankcase operation end as shown in the figure (TDC). Make sure that the 2V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference mark is opposite the indicator on the head, make the crankshaft turn once more. -The TDC reference mark is repeated also between the flywheel cooling fan and the flywheel cover. To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction of rotation using a compass spanner applied to the camshaft drive sprocket housing.
N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.
Checking the valve clearance

-To check valve clearance, centre the reference marks of the timing system. - Use a feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clearance values, intake and exhaust respectively, are different from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with a screwdriver.
Characteristic
Valve clearance Intake: 0.10 mm (when cold) Exhaust: 0.15 mm (when cold)
Braking system
MAIN - 40
Vespa LXV 125 i.e.
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 brake pads.
Top-up
Proceed as follows: - Remove the reservoir cap by loosening the two screws, remove the gasket and top-up using only the fluid 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; DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, REPLACE FLUID AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE. 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. Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4

MAIN - 41
Maintenance
Vespa LXV 125 i.e.
Brake pump reservoir screws 15 to 20
Headlight adjustment
Proceed as follows: 1. Position the vehicle in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; ensure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Turn on the headlight and check that the boundary of the light beam projected onto the screen is not higher than 9/10 or lower than 7/10 of the distance between the centre of the headlight and the ground; 3. Otherwise loosen the rear screw on just one side, press or pull the point of the headlight slightly to adjust its position.
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.
MAIN - 42
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
Vespa LXV 125 i.e.
Engine
See also
Troubleshooting procedure
Poor performance
POOR PERFORMANCE
Possible Cause Air filter blocked or dirty Operation Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Check it and replace, if necessary Replace the worn parts Check for causes and fill to reach the correct level Descale the cylinder, the piston, the head and the valves Time the system again or replace the worn parts Replace Check the rollers and the pulley movement, replace the damaged parts and lubricate the movable guide of the driven pulley with grease. Adjust the valve clearance properly Remove the head and the valves, grind or replace the valves Replace the head unit Replace the piston cylinder assembly or just the piston rings
Excessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Excess of scales in the combustion chamber Incorrect timing or worn timing system elements Muffler obstructed Inefficient automatic transmission
Wrong valve adjustment Overheated valves Valve seat distorted Worn cylinder, Worn or broken piston rings
Starting difficulties
DIFFICULTY STARTING UP
Possible Cause Flat battery Operation Check the state of the battery. If it shows signs of sulphation, replace it and bring the new battery into service by charging it for not more than ten hours at a current of 1/10 of the capacity of the battery itself. Replace the spark plug Inspect the head and/or restore the correct clearance Check starter motor. Drain off the fuel no longer up to standard; then, refill Remove the sponge, wash with water and car shampoo, then soak it in a mixture of 50% petrol and 50% specific oil. Press with your hand without squeezing, allow it to drip dry and refit. Check the pump.
Faulty spark plug Incorrect valve sealing or valve adjustment Starter motor and start-up system fault Altered fuel characteristics Air filter obstructed or dirty.
Fuel pump fault
Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION
Possible Cause Operation Wrong valve adjustment Adjust the valve clearance properly Overheated valves Remove the head and the valves, grind or replace the valves Misshapen/worn valve seats Replace the head unit Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings fitted properly Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal Worn valve oil guard Replace the valve oil seal Worn valve guides Check and replace the head unit if required
TROUBL - 44
Vespa LXV 125 i.e.
Troubleshooting
Insufficient lubrication pressure

POOR LUBRICATION PRESSURE
Possible Cause By-Pass remains open Oil pump with excessive clearance Oil filter too dirty Oil level too low Operation Check the By-Pass and replace if required. Carefully clean the By-Pass area. Perform the dimensional checks on the oil pump components Replace the cartridge filter Restore the level adding the recommended oil type
Transmission and brakes Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause Slippage or irregular functioning Operation Check that there is no grease on the masses. Check that the faying surface between the clutch masses and the clutch housing is mainly in the middle and with equivalent specifications on the three masses. Check that the clutch housing is not scored or worn abnormally
Insufficient braking
INEFFICIENT OR NOISY BRAKING
Possible Cause Worn brake pads or shoes Front brake disk loose or deformed Operation Replace the brake pads or shoes and check for brake disk or drum wear conditions. Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever). Failing elastic fittings, plunger or brake pump seals, replace Adjust the clearance with the appropriate adjuster located on the back part of the crankcase.
Air bubbles inside the hydraulic braking system Fluid leakage in hydraulic braking system Excessive clearance in the rear brake control cable
Brakes overheating
BRAKES OVERHEATING
Possible Cause Rubber gaskets swollen or stuck Compensation holes on the pump clogged Brake disc slack or distorted Operation Replace gaskets. Clean carefully and blast with compressed air Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Check calliper and replace any damaged part.
Defective piston sliding
Electrical system
TROUBL - 45
Troubleshooting
Vespa LXV 125 i.e.
Battery
BATTERY
Possible Cause Battery Operation The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 5 to 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

STEERING HARDENING
Possible Cause 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: if they are recessed or if the balls are squashed, replace them.
Excessive steering play

EXCESSIVE STEERING CLEARANCE
Possible Cause Excessive steering clearance Operation Check the tightening of the top ring nut. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.
Noisy suspension
NOISY SUSPENSION
Possible Cause NOISY SUSPENSION Operation If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly.
Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION
Possible Cause Faulty or broken seals Operation Replace the shock absorber Check the condition of wear of the steering covers and the adjustments.
TROUBL - 46
Vespa LXV 125 i.e.
Troubleshooting
TROUBL - 47
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Vespa LXV 125 i.e.
Electrical system
Key: 1. Magneto flywheel 2. Voltage regulator 3. Battery 12V-10 Ah 4. Starter relay 5. Starter motor 6. Starter button 7. Fuse No.1 - 20A 8. Fuse No.2 - 7.5A 9. Stop light bulb 10. ignition key contacts 11. Low beam light solenoid 12. Stop buttons 13. Light switch 14. Fuse No.5 - 7.5A 15. Fuse No.6 - 15A 16. Fuse No.4 - 7,5A 17. Front and rear daylight running light bulbs and license plate light 18. Headlight with twin-filament bulb 19. Pre-installation for anti-theft device ELE SYS - 49
Electrical system
Vespa LXV 125 i.e.
20. Turn indicator bulbs 21. Turn indicator switch 22. Turn indicator control device 23. Instrument panel bulb 24. Fuel level transmitter 25. Oil pressure sensor 26. Fuse No.3 - 7.5A 27. Immobilizer aerial 28. Injection electronic control unit 29. Fuel system pump 30. Diagnostics socket 31. Engine temperature sensor 32. Fuel injector 33. HV coil 34. Engine speed sensor 35. Lambda probe 36. Horn button 37. Horn 38. Injection load solenoid 39. High-beam light solenoid 40. Turn indicator warning light bulb 41. Bulb for oil pressure warning light 42. Fuel gauge 43. Low fuel warning light bulb 44. Bulb for engine control telltale light 45. Immobilizer 46. Bulb for high beam headlight warning light 47. Engine stop switch 48. Ground on the chassis 49. Earth braid 50. Ground on the engine 51. Condenser 52. Resistance 53. Immobilizer LED warning light 54. Resistance KEY
ELE SYS - 50
Vespa LXV 125 i.e.
Electrical system
Ar: Orange Az: Light blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
Key: 1. Left turn indicator bulbs 2. Right turn indicator bulbs 3. Turn indicator warning light bulb 4. Turn indicator switch 5. Turn indicator control device 6. Pre-installation for anti-theft device 7. Headlight with twin-filament bulb 8. Bulb for high beam headlight warning light 9. Front daylight running light bulb 10. Rear tail light bulb 11. License plate bulb 12. Instrument panel lighting bulbs 13. engine stop switch 14. Fuses No. 3- 7.5A; No. 4- 7.5A; No. 5- 7.5A; No. 6- 15A; 15. High-beam light solenoid ELE SYS - 51
Electrical system
Vespa LXV 125 i.e.
16. Low beam light solenoid 17. Light switch 18. Stop buttons 19. Ignition switch contacts 20. Fuse No.2 - 7.5A 21. Earth braid 22. Starter motor 23. Starter remote control switch 24. Starter button 25. Fuse No.1 - 20A 26. 12v-10Ah battery 27. Magneto flywheel 28. Voltage regulator 29. Stop light bulb 30. Injection load relay 31. Horn button 32. Horn 33. Lambda probe 34. Engine speed sensor 35. HV coil 36. Fuel injector 37. Engine temperature sensor 38. Fuel system pump 39. Diagnostics socket 40. Injection electronic control unit 41. Immobilizer antenna 42. Bulb for engine control telltale light 43. Fuel level transmitter 44. Fuel gauge 45. Low fuel warning light bulb 46. Oil pressure sensor 47. Bulb for oil pressure warning light 48. Immobilizer LED warning light KEY Ar: Orange Az: Light blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
ELE SYS - 52
Vespa LXV 125 i.e.
Electrical system
Components arrangement
ELE SYS - 53
Electrical system
Vespa LXV 125 i.e.
1. Magneto flywheel - Remove the flywheel cover, as described in the Engine chapter, to reach it. To get access to the connectors, remove the helmet compartment.
2. Voltage regulator - Remove the front central cover to reach it.
3. Battery - Lift the saddle and remove the cover to reach them.
4. Starter remote control - Remove the battery to reach it.
ELE SYS - 54
Vespa LXV 125 i.e.
Electrical system
7 - 8 - 14 - 15 - 16 -26. Fuses - Remove the battery cover and/or the front central cover to reach them.
11 - 38 - 39. Remote controls - Remove the front central cover to reach it.
29 - 24. Pump and fuel lever transmitter - They are fitted on the tank, remove the fuel tank to reach them.
ELE SYS - 55
Electrical system
Vespa LXV 125 i.e.
25 - 34. Oil pressure sensor - engine speed sensor - To reach it, remove the fan cover cap, as described in ENGINE chapter.
27. Immobilizer aerial- Remove the shield back plate to reach it.
28. Injection ECU - Remove the helmet compartment to reach it.
30. Diagnosis connector - Remove the helmet compartment to reach it.
ELE SYS - 56
Vespa LXV 125 i.e.
Electrical system
31 - 32. Engine temperature sensor - fuel injector - Remove the helmet compartment to reach it.
33. H.V. coil - Remove the helmet compartment and undo the two screws indicated to reach it.
Ground points
On the vehicle there is a chassis ground point, marked with letter "A", on the right side of the battery compartment.
ELE SYS - 57
Electrical system
Vespa LXV 125 i.e.
There is another ground point "B" on the starter motor.
On the left side of the chassis, under the footrest, there is the chassis-engine ground lead "C".
Electrical system installation
ELE SYS - 58
Vespa LXV 125 i.e.
Electrical system
Back side
1. To the front part 2. To the magneto flywheel 3. To HV coil 4. To the rear lighting devices 5. Chassis ground 6. Start-up remote control switch 7. Fuel level transmitter 8. Battery 9. Diagnostic socket 10.Generator connector 11.Pick-up connector
ELE SYS - 59
Electrical system
Vespa LXV 125 i.e.
1. Rear right turn indicator 2. License plate light 3. To rear light 4. Rear left turn indicator 5. Fuel pump 6. To the fuel level transmitter 7. Diagnostic socket 8. Generator connector 9. Pick-up connector 10.HV coil 11.Lambda sensor 12.Lambda probe connector
ELE SYS - 60
Vespa LXV 125 i.e.
Electrical system
1. Fuse box 2. Start-up remote control switch 3. Battery 4. Fuel pump 5. Fuel level transmitter 6. Injector 7. Engine temperature sensor 8. Injection ECU 9. Start-up motor ground 10.Start-up motor positive terminal 11.Diagnostic socket 12.HV coil 13.Generator connector 14.Pick-up connector ELE SYS - 61
Electrical system
Vespa LXV 125 i.e.
15.To the spark plug 16.chassis - engine ground lead 17.To the front part
Conceptual diagrams Ignition
Key: 3. Battery 12V-10 Ah 7. Fuse No.1 - 20A 8. Fuse No.2 - 7,5A 10. ignition key contacts 13. Light switch 15. Fuse No.6 - 15A 26. Fuse No.3 - 7.5A 27. Immobilizer aerial 28. Injection electronic control unit 29. Fuel system pump 30. Diagnostics socket 32. Fuel injector ELE SYS - 62
Vespa LXV 125 i.e.
Electrical system
33. HV coil 38. Injection load solenoid 44. Bulb for engine control telltale light 45. Immobilizer 51. Condenser 52. Resistance 53. Immobilizer LED warning light 54. Resistance THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
Key: 14. Fuse No.6 - 15A 19. Ignition switch contacts 20. Fuse No.2 - 7.5A 25. Fuse No.1 - 20A 26. 12v-10Ah battery 30. Injection load relay 35. HV coil 40. Injection electronic control unit 41. Immobilizer antenna ELE SYS - 63
Electrical system
Vespa LXV 125 i.e.
48. Immobilizer LED warning light
Battery recharge and starting
Key: 1. Magneto flywheel 2. Voltage regulator 3. Battery 12V-10 Ah 4. Starter relay 5. Starter motor 6. Starter button 7. Fuse No.1 - 20A 8. Fuse No.2 - 7.5A 9. Stop light bulb 10. ignition key contacts 12. Stop buttons 15. Fuse No.6 - 15A 26. Fuse No.3 - 7.5A 28. Injection electronic control unit THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. ELE SYS - 64
Vespa LXV 125 i.e.
Electrical system
Key: 14. Fuses No. 3- 7.5A; 18. Stop buttons 19. Ignition switch contacts 22. Starter motor 23. Starter remote control switch 24. Starter button 25. Fuse No.1 - 20A 26. 12v-10Ah battery 27. Magneto flywheel 28. Voltage regulator 29. Stop light bulb 40. Injection electronic control unit
ELE SYS - 65
Electrical system
Vespa LXV 125 i.e.
Level indicators and enable signals section
Key: 7. Fuse No.1 - 20A 8. Fuse No.2 - 7.5A 10. ignition key contacts 15. Fuse No.6 - 15A 24. Fuel level transmitter 25. Oil pressure sensor 26. Fuse No.3 - 7.5A 28. Injection electronic control unit 31. Engine temperature sensor 32. Fuel injector 34. Engine speed sensor 35. Lambda probe 38. Injection load solenoid 41. Bulb for oil pressure warning light 42. Fuel gauge 43. Low fuel warning light bulb 44. Bulb for engine control telltale light
ELE SYS - 66
Vespa LXV 125 i.e.
Electrical system
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
Key: 13. engine stop switch 14. Fuses No. 3- 7.5A; No. 6- 15A 19. Ignition switch contacts 20. Fuse No.2 - 7.5A 25. Fuse No.1 - 20A 26. 12v-10Ah battery 40. Injection electronic control unit 41. Immobilizer antenna 43. Fuel level transmitter 44. Fuel gauge 45. Low fuel warning light bulb 46. Oil pressure sensor 47. Bulb for oil pressure warning light 48. Immobilizer LED warning light
ELE SYS - 67
Electrical system
Vespa LXV 125 i.e.
Devices and accessories
Key: 3. Battery 12V-10 Ah 7. Fuse No.1 - 20A 8. Fuse No.2 - 7.5A 9. Stop light bulb 10. ignition key contacts 15. Fuse No.6 - 15A 16. Fuse No.4 - 7.5A 19. Pre-installation for anti-theft device 20. Turn indicator bulbs 21. Turn indicator switch 22. Turn indicator control device 26. Fuse No.3 - 7.5A 27. Immobilizer aerial 28. Injection electronic control unit 29. Fuel system pump 36. Horn button 37. Horn
ELE SYS - 68
Vespa LXV 125 i.e.
Electrical system
38. Injection load solenoid 40. Turn indicator warning light bulb 44. Bulb for engine control telltale light 45. Immobilizer 51. Condenser 52. Resistance 53. Immobilizer LED warning light 54. Resistance
Key: 1. Left turn indicator bulbs 2. Right turn indicator bulbs 6. Pre-installation for anti-theft device 14. Fuses No. 3- 7.5A; No. 4- 7.5A 19. Ignition switch contacts 25. Fuse No.1 - 20A 26. 12v-10Ah battery 31. Horn button
ELE SYS - 69
Electrical system
Vespa LXV 125 i.e.
32. Horn
Lights and turn indicators
Key: 3. Battery 12V-10 Ah 7. Fuse No.1 - 20A 8. Fuse No.2 - 7.5A 9. Stop light bulb 10. ignition key contacts 11. Low beam light solenoid 12. Stop buttons 13. Light switch 14. Fuse No.5 - 7.5A 15. Fuse No.6 - 15A 16. Fuse No.4 - 7.5A 17. Front and rear daylight running light bulbs and license plate light 18. Headlight with twin-filament bulb 20. Turn indicator bulbs 21. Turn indicator switch 22. Turn indicator control device ELE SYS - 70
Vespa LXV 125 i.e.
Electrical system
23. Instrument panel bulb 26. Fuse No.3 - 7.5A 28. Injection electronic control unit 39. High-beam light solenoid 40. Turn indicator warning light bulb 46. Bulb for high beam headlight warning light 47. Engine stop switch THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
Key: 1. Left turn indicator bulbs 2. Right turn indicator bulbs 3. Turn indicator warning light bulb 4. Turn indicator switch 5. Turn indicator control device 7. Headlight with twin-filament bulb 8. Bulb for high beam headlight warning light 9. Front daylight running light bulb 10. Rear tail light bulb 11. License plate bulb ELE SYS - 71
Electrical system
Vespa LXV 125 i.e.
12. Instrument panel lighting bulbs 14. Fuses No. 3- 7.5A; No. 4- 7.5A; No. 5- 7.5A 15. High-beam light solenoid 16. Low beam light solenoid 17. Light switch 19. Ignition switch contacts 25. Fuse No.1 - 20A 26. 12v-10Ah battery 40. Injection electronic control unit INJECTION
Key: 13. engine stop switch 14. Fuses No. 3- 7.5A; No. 6- 15A 15. High-beam light solenoid 16. Low beam light solenoid 19. Ignition switch contacts 20. Fuse No.2 - 7.5A 23. Starter remote control switch 25. Fuse No.1 - 20A 26. 12v-10Ah battery ELE SYS - 72
Vespa LXV 125 i.e.
Electrical system
30. Injection load relay 33. Lambda probe 34. Engine speed sensor 35. HV coil 36. Fuel injector 37. Engine temperature sensor 38. Fuel system pump 39. Diagnostics socket 40. Injection electronic control unit 41. Immobilizer antenna 42. Bulb for engine control telltale light 48. Immobilizer LED warning light
Checks and inspections Immobiliser

The electronic ignition system is managed by the control unit in which the immobiliser system is integrated. The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means of the coded keys that the control unit recognises. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobilizer system consists of the following components: - Control unit - Immobilizer aerial - master and service keys with built-in transponder - HV coil - diagnosis LED The diagnosis led also works as a blinking light to deter theft. This function is activated every time the ignition key is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process.
ELE SYS - 73
Electrical system
Vespa LXV 125 i.e.
When the ignition key is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition key and/or the instrument panel is not initiated, check if: there is battery voltage that fuse 1 and fuse 6 are in good conditions. there is power to the control unit as specified below: Remove the connector mounting bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: there is battery voltage between terminals 6-26 and terminal 6-chassis ground (fixed power supply). If there is no voltage check that fuse 3 and its cable are in working order.
With the key switch set to ON: there is battery voltage between terminals 5-26 and terminal 5-chassis ground (fixed power supply). If there is no voltage, check the ignition key contacts, that fuse 2 and its cable are in working order.
ELE SYS - 74
Vespa LXV 125 i.e.
Electrical system
After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture.
Remove the protective base from the connector.
With the ignition switch at ON check there is battery voltage between the Red-White and Black cables
With MIU connector disconnected, check the continuity between the Orange-White cable and pin 7 of the interface wiring.
Specific tooling
020481Y Control unit interface wiring 020331Y Digital multimeter
ELE SYS - 75
Electrical system
Vespa LXV 125 i.e.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means of the coded keys that the control unit recognises. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobilizer system consists of the following components: - Control unit - Immobilizer aerial - master and service keys with built-in transponder - H.V. coil - diagnosis LED The diagnosis led also works as a blinking light to deter theft. This function is activated every time the ignition switch is turned to "OFF" and it remains active 48 hours so as not to damage the battery charging process. When the ignition switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The duration of the flash depends on the programming of the electronic control unit.
ELE SYS - 76
Vespa LXV 125 i.e.
Electrical system
If the LED is off regardless of the position of the ignition switch and/or the instrument panel is not initiated, check if: there is battery voltage fuse No. 1, fuse No. 2 and fuse No. 6 efficiency. there is power to the control unit as specified below: Remove the connector mounting bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: there is battery voltage between terminals 7-9 and terminal 9-chassis ground (fixed power supply). If there is no voltage, check that fuse 6 and its cable harness are in working order.
With the key switch in the ON position: there is battery voltage between terminals 6-7 and terminal 6-chassis ground (fixed power supply). If there is no voltage, check the ignition switch contacts, that fuse 2 and its cable are in working order.
After removing the leg shield back plate, remove the electrical connection from the aerial as shown in the picture.
ELE SYS - 77
Electrical system
Vespa LXV 125 i.e.
Remove the protective base from the connector.
With the ignition switch at ON check there is battery voltage between the Red-White and Black cables
With MIU connector disconnected, check the continuity between the Orange-White cable and pin 14 of the control unit.
Specific tooling
ELE SYS - 78
Vespa LXV 125 i.e.
Electrical system
Virgin circuit
When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly. The data storage procedure for a previously unprogrammed control unit provides for the recognition of the red key (master key) as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys. The master and service keys must be used to code the system as follows: - Insert the Master key, turn it to ON and keep this position for two seconds (lower and upper limits 1 to 3 seconds). - Insert the blue key and set to ON for 2 seconds. - If you have copies of the key, repeat the operation with each key. - Insert the MASTER key again and turn it to ON for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys (blue) can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must re-
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peat the procedure using all the keys you intend to keep using. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected. In any case it is advisable to use resistive spark plugs.
Characteristic
Shielded cap resistance ~ 5000 .
Diagnostic codes
The Immobilizer system is tested each time the ignition key is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be identified and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the LED remains off permanently, the ignition is enabled. If, however, the LED remains on permanently, it means the ignition is inhibited: 1. Previously unused control unit - key inserted: a single 2 second flash is displayed, after which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs. 2. Previously unused control unit - transponder absent or cannot be used: the LED is on permanently. In this condition no operations are possible including the start up of the vehicle.
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3. Programmed control unit - the service key in (normal condition of use): a single 0.7-second flash is displayed, after which the LED remains off steadily. The engine can be started. 4. Programmed control unit - Master key in: a 0.7-sec flash is displayed followed by the LED remaining off for 2 sec and then by short 0.46-sec flashes, the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been completed, the LED remains permanently OFF. The engine can be started. 5. Programmed control unit - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be transmitted are: 1-flash code 2-flash code 3-flash code
Diagnostic code - 1 flash

A one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer antenna wiring and change it if necessary.
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Diagnostic code - 2 flashes

A two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobilizer antenna or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. If this is not the case, replace the defective key and/or reprogram the control unit. Replace the control unit if the problem continues.
Diagnostic code - 3 flashes

A three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit. If this is not the case, reprogram the decoder.
Battery recharge circuit

The charging circuit consists of three-phase alternator and a permanent magneto flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery's positive terminal passing through the 20A protective fuse. The three-phase alternator provides good recharge power and at low revs a good compromise is achieved between generated power and idle stability.
Stator check
Checking the stator windings
WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. 1) Lift the saddle and remove the helmet compartment. 2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the picture. ELE SYS - 82
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3) Measure the resistance between each of the yellow terminals and the other two.
Electric characteristic
Resistance: 0.2 - 1 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator.
Recharge system voltage check

Look for any leakage 1) Access the battery by removing the specific cover. 2) Check that the battery does not show signs of losing fluid before checking the output voltage. 3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery. 4) With the ignition key always at OFF, the reading indicated by the ammeter must be 0.5 mA. Charging current check
WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER. 1) Place the vehicle on its centre stand 2) With the battery correctly connected to the circuit, place the multimeter leads between the battery terminals.. 3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.
Voltage ranging between 14.0 and 15.0V at 5000 rpm. Maximum current output check. - With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V. - Connect ammeter pliers to the 2 recharge positive poles in output from the regulator. - Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A
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VOLTAGE REGULATOR/RECTIFIER
Specification Type Voltage Desc./Quantity Non-adjustable three-phase transistor 14 to 15V at 5000 rpm with lights off
Starter motor
KEY 1. Battery 2. Starter remote control 3. Fuse No. 1 4. Fuse No. 6 5. Ignition key contacts 6. Fuse No. 2 7. Electronic control unit 8. Starter motor 9. Stop buttons 10. Fuse No. 3 11. Starter button
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 1, 2, 3 and 6. 2) Check ignition key contacts. 3) Check the contacts of the stop buttons and the starter button. ELE SYS - 84
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4) With the ignition key set to ON, the brake pulled and the starter button pressed, check if there is voltage between the Orange-White cable of the start-up remote control switch and the ground connection. If there is not, check the cable harnesses. 5) Check the start-up remote control switch. 6) Check that the Red cable between the battery and the start-up remote control switch is not interrupted. Also check continuity between the latter and the starter motor. 7) Check the starter motor ground connection. 8) Check that the Orange-Blue cable between the start-up remote control switch and the control unit (pin 24) is not interrupted. THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
KEY 1. Battery 2. Starter relay 3. Fuse No. 1 4. Fuse No. 6 5. Ignition switch contacts 6. Fuse No. 2 7. Electronic control unit 8. Starter motor 9. Stop buttons ELE SYS - 85
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10. Fuse No. 3 11. Starter button

WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 1, 2, 3 and 6. 2) Check ignition switch contacts. 3) Check the contacts of the stop buttons and the starter button. 4) With the ignition switch set to ON, the brake pulled and the starter button pressed, check if there is voltage between the Orange-White cable of the start-up relay and the ground connection. If there is not, check the cable harnesses. 5) Check the starter relay. 6) Check that the Red cable between the battery and the starter relay is not interrupted. Also check continuity between the latter and the starter motor. 7) Check the starter motor ground connection. 8) Check that the Orange-Blue cable between the starter relay and the control unit (pin 10) is not interrupted.
Horn control
KEY 1. Battery 2. Fuse No. 1 ELE SYS - 86
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3. Ignition switch contacts 4. Fuse No. 3 5. Horn button 6. Horn

WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 1 and 3. 2) Check the ignition switch and horn button contacts. 3) With the ignition switch set to ON and the horn button pressed, check if there is voltage between the Grey-Black cable of the horn device and the ground connection. If there is not, check the cable harnesses. 4) Check the horn device ground connection.
Turn signals system check
KEY 1. Battery 2. Fuse No. 1 3. Ignition key contacts 4. Fuse No. 3 5. Turn indicator control device 6. Turn indicator switch 7. Turn indicator bulbs (12V - 10W) ELE SYS - 87
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8. Turn indicator warning light bulb

WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check that bulbs operate properly. 2) Check fuses No. 1 and 3. 3) Check ignition switch contacts. 4) With the ignition key set to ON, check if there is voltage between the Blue-Black cable of the turn indicators switch and the ground connection. If there is not, check the cable harnesses and the connections of the turn indicator control device. 5) Check the turn indicator switch contacts. 6) With the turn indicator switch pressed to the right, check if there is voltage between the White-Blue cable of the switch and the ground connection. If there is not, check the cable harnesses. 7) With the turn indicator switch pressed to the left, check if there is voltage between the Pink cable of the switch and the ground connection. If there is not, check the cable harnesses. 8) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If faults are detected: 1) With a multimeter, check resistance values between the White-Green cable and the Black cable of the fuel level transmitter under different conditions. 2) If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted.
Resistance value when the tank is full <= 7 Resistance value when the tank is empty 90 +13/-3
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Electrical system
Lights list
KEY 1. Battery 2. Fuse No. 1 3. Fuse No. 4 4. ignition key contacts 5. Low beam light solenoid 6. Fuse No. 5 7. Electronic control unit 8. Daylight running lights, license plate lamp (12V - 5W) and dashboard lighting bulb (12V - 1.2W) 9. Low/high beam twin-filament bulb (12V - 55/60W) 10. Light switch 11. High-beam light solenoid 12. High beam warning light 13. Fuse No. 3
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. LINE FOR DAYLIGHT RUNNING LIGHTS, LICENSE PLATE LIGHT AND DASHBOARD LIGHTING BULB 1) Check that bulbs operate properly. 2) Check fuses No. 1 and 5. 3) Check ignition key contacts. ELE SYS - 89
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4) Check if there is voltage between the Yellow-Black cable of fuse No. 5 and the ground. If not, check cable harnesses. 5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted. HIGH BEAM/LOW BEAM LIGHTS LINE 1) Check that bulbs operate properly. 2) Check fuses No. 1, 3 and 4. 3) Check ignition key contacts. 4) Check the voltage between the Grey cables (30) of the low and high beam light solenoids and the ground, if not check the cable harnesses. 5) With the ignition key set to ON and the engine running, check if there is voltage between the Violet cable (87) of the headlight solenoid and the ground connection. If there is not, check cable harnesses. 6) With the ignition key set to ON and the engine running, check if there is voltage between the Brown cable (87) of the high-beam light solenoid and the ground connection. If there is not, check cable harnesses. 7) Check the continuity of the White-Black cables that connect the low and high beam light solenoids to the control unit (pin 19). 8) Check low and high beam light solenoids. 9) Check the light switch contacts. 10) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
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KEY 1. Battery 2. Fuse No. 1 3. Key switch contacts 4. Light switch 5. Low/high beam twin-filament bulb (12V - 55/60W) 6. High beam warning light 7. High-beam light solenoid 8. Low beam light solenoid 9. Fuse No. 4 10. Fuse No. 3 11. Fuse No. 5 12. Daylight running lights, license plate lamp (12V - 5W) and dashboard lighting bulb (12V - 1.2W) 13. Electronic control unit
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. LINE FOR DAYLIGHT RUNNING LIGHTS, LICENSE PLATE LIGHT AND DASHBOARD LIGHTING BULB 1) Check that bulbs operate properly. 2) Check fuses No. 1 and 5. 3) Check ignition switch contacts. 4) With the ignition switch set to ON, check the presence of the voltage between the yellow/black cable of the fuse No. 5 and the ground. If there is not, check the cable harnesses. 5) Check that the cable harnesses of the bulbs and their ground connection are not interrupted. HIGH BEAM/LOW BEAM LIGHTS LINE 1) Check that bulbs operate properly. 2) Check fuses No. 1, 3 and 4. 3) Check ignition switch contacts. 4) Check the presence of voltage between the grey (30) cables of the low and high beam light solenoids and the ground. If there is not, check the cable harnesses. 5) With the ignition switch set to ON, with the engine on and light switch set to high beam, check the presence of voltage between the purple (87) cable of the high-beam light solenoid and the ground. If there is not, check the cable harnesses. 6) With the ignition switch set to ON, with the engine on and light switch set to low beam, check the presence of voltage between the brown (87) cable of the low-beam light solenoid and the ground. If there is not, check the cable harnesses. 7) Check the continuity of the White-Black cables that connect the low and high beam light solenoids to the control unit (pin 33). ELE SYS - 91
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8) Check low and high beam light solenoids. 9) Check the light switch contacts. 10) Check that the cable harnesses of the bulbs and their ground connection are not interrupted.
Fuses
The electrical system is equipped with: 1. four protection fuses A that can be reached by removing the shield front cover. 2. two fuses B, located in the battery compartment. The chart shows the position and specifications of the fuses in the vehicle.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE). CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM CAN CAUSE MALFUNCTIONING AND RISK OF FIRE.
FUSES
1 2 3 4 5 6 Specification Fuses No. 4 - Current rating: 7.5 A Fuses No. 3 - Current rating: 7.5 A Fuses No. 5 - Current rating: 7.5A Fuses No. 2 - Current rating: 7.5A Fuses No. 1 - Current rating: 20A Fuses No. 6 - Current rating: 15A Desc./Quantity Protected circuits: Battery-powered, lights remote control and antitheft-device pre-installation. Protected circuits: Live accessories, instrument panel, horn, stop buttons and start-up remote control. Protected circuits: Live, daylight running lights and dashboard lighting. Protected circuits: Live, coil, injection load remote control, immobilizer aerial and MIU. Protected circuits: Vehicle main fuse. Protected circuits: Battery-powered injection loads, injection ECU and immobilizer LED.
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Dashboard
A = Fuel gauge B = High-beam warning light C = Turn indicator warning light D = Odometer E = Speedometer F = Low fuel warning light G = Low engine oil pressure warning light H = Engine control telltale light I = Immobilizer LED
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a standard tester. - If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode - Constant voltage charge equal to 14.40 to 14.70V - Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h
Battery installation
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)
WARNING
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BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN 1) Battery preparation Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.
2) Electrolyte preparation. Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulphuric acid.
3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping. 4) Control the flow of electrolyte Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery. ELE SYS - 94
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5) Take out the container. Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point. 6) Battery closing. Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery. 7) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged. If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle. The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between 12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).
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d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.
f - Check the ignition of the green LED indicated with a red arrow in figure.
g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place
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h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
Sensore di temperatura
Key: 1. Engine temperature sensor
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With the connector control unit side disconnected and the coolant temperature sensor connector connected, check the resistance between pins 9 and 26 in relation to the engine temperature. 20C = 3502 237 ohm 80C = 357 19 ohm With the connector control unit side disconnected and the engine temperature sensor connector disconnected, check the insulation between the two Light Blue-Green and Grey-Green cables.
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Key: 1. Engine temperature sensor With the connector on the control unit side disconnected and the engine temperature sensor connector connected, check that the resistance values between pin 13 and 7 and the ground lead correspond with the engine temperature. 20C = 3502 237 ohm 80C = 357 19 ohm With the connector on the control unit side disconnected and the engine temperature connector disconnected, check the insulation between the lightblue/green and grey/green cables.
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Connectors
DIAGNOSTICS CONNECTOR 1. Not connected 2. Ground lead (Black) 3. Electronic control unit (Violet - White)
PICKUP CONNECTOR 1. Control unit positive (Red) 2. Negative from control unit (Brown) 3. Not connected
FUEL PUMP CONNECTOR 1. Not connected 2. Ground lead (Black) 3. Not connected 4. Not connected 5.Power from relay (Black - Green)
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ELECTRONIC CONTROL UNIT CONNECTOR 1. Injection telltale light (Brown-Black) 2. Not connected 3. Not connected 4. Lambda probe negative (White-Green) 5. Live supply (Red-White) 6. Battery-powered (Grey-Black) 7. Immobilizer aerial (Orange-White) 8. Not connected 9. Engine temperature sensor (Sky blue-Green) 10. Not connected 11. Lambda probe positive (Sky blue-Black) 12. Engine stop switch (Green-Black) 13. Engine speed sensor positive (Red) 14. Injector (Red-Yellow) 15. Engine speed sensor negative (Brown) 16. Diagnosis (Purple-White) 17. Immobilizer warning light (Red-Green) 18. To ground (Grey-Green) 19. Low beam lights automatic ignition (WhiteBlack) 20. Injection load remote control (Black-Purple) 21. Lambda probe (Green - Yellow) 22. HV coil (Pink-Black) 23. Not connected 24. Starter enabling (Orange-Blue) 25. Not connected 26. Ground lead (Black) ENGINE TEMPERATURE SENSOR CONNECTOR 1. Electronic control unit (Sky blue - Green) 2. Ground lead (Grey-Green)
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INJECTOR CONNECTOR 1. Power from relay (Black - Green) 2. Electronic control unit (Red - Yellow)
LAMBDA PROBE CONNECTOR 1. Positive from control unit (Sky blue - Black) 2. Control unit negative (White - Green) 3. Electronic control unit (Green - Yellow) 4. Power from solenoid (Black - Green)
VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Black) 2. Ground lead (Black)
INSTRUMENT PANEL CONNECTOR 1. Indicator warning light (Pink) 2. Indicator warning light (White - Blue) 3. Live supply (White) 4. Low fuel warning light (Yellow-Green) 5. Oil pressure sensor (Pink-White) 6. High-beam warning light (Violet) 7. Ground lead (Black) 8. Lighting (Yellow - Black) 9. Immobilizer warning light (Red-Green) 10.Battery-powered (Grey-Black) 11.Fuel level indicator (White-Green)
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12. Engine management warning light (Brown Black) H.V. COIL CONNECTOR 1. Power from relay (Black - Green) 2. Electronic control unit (Pink - Black)
ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. Ground lead (Black) 2. Left indicator (White - Blue) 3. Right indicator (Pink) 4. Battery-powered (Grey) 5. Key powered (White) 6. Not connected 7. Not connected 8. Not connected IMMOBILIZER ANTENNA CONNECTOR 1. Key powered (Red-White) 2. Ground lead (Black) 3. Electronic control unit (Orange-White)
FUEL LEVEL TRANSMITTER CONNECTOR 1. Fuel level indicator (White - Green) 2. Ground lead (Black) 3.Low fuel warning light (Yellow-Green)
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. ELE SYS - 103
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DIAGNOSTICS CONNECTOR 1. Not connected 2. Ground lead (Black) 3. Electronic control unit (Violet - White)
PICK-UP CONNECTOR 1. Control unit positive (Red) 2. Negative from control unit (Brown) 3. Oil pressure sensor (Pink-White)
FUEL PUMP CONNECTOR 1. Not connected 2. Ground lead (Black) 3. Not connected 4. Not connected 5.Power from relay (Black - Green)
ELECTRONIC CONTROL UNIT CONNECTOR 1. H.V. COIL (Pink-Black) 2. Not connected 3. Not connected 4. Ground (Green-Black) 5. Not connected 6. Key powered(Red-White) 7. Ground No. 1 (Black) 8. Not connected 9. Battery-powered (Grey-Black) 10. Start-up enabling switch (Orange-Blue) 11. Lambda probe positive (Sky blue-Black) 12. Lambda probe negative (White-Green)
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13. Water temperature sensor (Sky blue-Green) 14. Immobilizer aerial (Orange-White) 15. Not connected 16. K serial line (Purple-White) 17. Immobilizer (Red-Green) 18. Not connected 19. Side stand (Grey-Green) 20. Engine speed sensor negative (Brown) 21. Not connected 22. Injection load relay (Black-Purple) 23. Not connected 24. Not connected 25. Injection warning light (Brown-Black) 26. Not connected 27. Not connected 28. Not connected 29. Engine speed sensor positive (Red) 30. Not connected 31. Lambda probe heater (Green-Yellow) 32. Not connected 33. Low beam lights automatic ignition enabling (White-Black) 34. Fuel injector (Red-Yellow) ENGINE TEMPERATURE SENSOR CONNECTOR 1. Electronic control unit (Sky blue - Green) 2. Ground lead (Grey-Green)
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INJECTOR CONNECTOR 1. Power from relay (Black - Green) 2. Electronic control unit (Red - Yellow)
LAMBDA PROBE CONNECTOR 1. Positive from control unit (Sky blue - Black) 2. Control unit negative (White - Green) 3. Electronic control unit (Green - Yellow) 4. Power from solenoid (Black - Green)
VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Black) 2. Ground lead (Black)
INSTRUMENT PANEL CONNECTOR 1. Indicator warning light (Pink) 2. Indicator warning light (White - Blue) 3. Live supply (White) 4. Low fuel warning light (Yellow-Green) 5. Oil pressure sensor (Pink-White) 6. High-beam warning light (Violet) 7. Ground lead (Black) 8. Lighting (Yellow - Black) 9. Immobilizer warning light (Red-Green) 10.Battery-powered (Grey-Black) 11.Fuel level indicator (White-Green)
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12. Engine management warning light (Brown Black) H.V. COIL CONNECTOR 1. Power from relay (Black - Green) 2. Electronic control unit (Pink - Black)
ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. Ground lead (Black) 2. Left indicator (White - Blue) 3. Right indicator (Pink) 4. Battery-powered (Grey) 5. Key powered (White) 6. Not connected 7. Not connected 8. Not connected IMMOBILIZER ANTENNA CONNECTOR 1. Key powered (Red-White) 2. Ground lead (Black) 3. Electronic control unit (Orange-White)
FUEL LEVEL TRANSMITTER CONNECTOR 1. Fuel level indicator (White - Green) 2. Ground lead (Black) 3.Low fuel warning light (Yellow-Green)
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Vespa LXV 125 i.e.
Diagnostic instrument
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. STARTER COMMAND Function Commands engine starting through the injection control unit. Operation / Operating principle The starter button, the brake switches, the starter command relay and the injection control unit are involved with Pin 10. ELECTRICAL ERRORS Starter command P0170 - shorted to positive. Error cause Short circuit to positive: excessive voltage at PIN 10 of the control unit connector. Troubleshooting Short circuit to positive: - This malfunction is detected with a brake activated and the starter button pressed. - If the battery voltage does not drop (thanks to the absorption of the starter command relay excitation coil) the control unit understands that PIN 10 is shorted to battery. - Restore the cabling (if the short is in the cabling) or the relay (if the short is in the relay). THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. ENGINE TEMPERATURE SENSOR Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Pinout: 1. Injection ECU 2. Ground from control unit Engine temperature sensor P0115 - open circuit or shorted to positive / shorted to negative. Error cause Open circuit or short circuit to positive:interruption of the circuit or excessive voltage at PIN 13 of the control unit connector. Short circuit to negative: null voltage between PIN 13 and 7 of the control unit connector. Troubleshooting Open circuit: ELE SYS - 108
Vespa LXV 125 i.e.
Electrical system
- Disconnect the connector of the control unit. - Measure the resistance value of the sensor at different temperatures between PIN 13 and 7. - Disconnect the sensor connector. - Check the continuity of the cable harness between the sensor connector and control unit connector: Control unit PIN 13 - sensor PIN 1 and control unit PIN 7 - sensor PIN 2. If necessary, restore the cable harness. - If the cabling is intact but the sensor resistance value is incorrect, this means that the sensor is faulty and must be replaced, otherwise proceed with the checks. Short circuit to positive: - With the sensor connector and the control unit disconnected, verify that the fault is shorted with the battery positive of sensor connector PIN 1 (or control unit PIN 13) and restore the cabling. Short circuit to negative: - Disconnect the sensor connector. - Check the sensor connector PIN 1 ground insulation. - If there is no ground insulation restore the cabling. - If PIN 1 is insulated from the ground and the error persists, this means that there is a probable fault in the control unit.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. LAMBDA PROBE Function In charge of telling the control unit whether the mixture is lean or rich. Operation / Operating principle Based on the difference of oxygen in the exhaust fumes and the environment, this generates voltage which is read and interpreted by the injection control unit. It does not require an external supply source but, in order to work properly, it should reach a high operating temperature: that is why there is a heating circuit inside. Pin-out: 1. Positive from control unit 2. Negative from control unit 3. Negative heater from control unit 4. Heater supply from relay ELECTRICAL ERRORS
ELE SYS - 109
Electrical system
Vespa LXV 125 i.e.
Check the air-fuel ratio / Lambda probe P0130 - Shorted to positive / open circuit, shorted to negative or carburetion excessively lean / signal not plausible for abnormal title correction or probe signal fault. Error cause Short circuit to positive: excessive voltage at PIN 11 or PIN 12 of the control unit connector. Circuit open or short circuit to negative: interruption of the circuit or null voltage between control unit connector PIN 11 and 12. Troubleshooting Short circuit to positive: - Disconnect the control unit connector and the sensor connector. - Verify that there is no short circuit with the battery positive on the PIN 1 of the sensor connector (corresponding to the PIN 11 of the control unit connector); in the presence of short circuit, restore the cable harness. - Verify that there is no short circuit with the battery positive on the PIN 2 of the sensor connector (corresponding to the PIN 12 of the control unit connector); in the presence of short circuit, restore the cable harness. Open circuit: - Disconnect the control unit connector and the sensor connector. - Check the continuity of the cable harness between the sensor connector and control unit connector: PIN 11 of the control unit - PIN 1 of the sensor and PIN 12 of the control unit - PIN 2 of the sensor. If necessary, restore the cable harness. - If the cable harness is intact and the error persists, proceed with the following checks. Short circuit to negative: - Disconnect the sensor connector and the control unit connector. - Check the sensor connector PIN 1 ground insulation. If there is no insulation, restore the cable harness. - Check the insulation from the ground of PIN 2 of the sensor connector. If there is no insulation, restore the cable harness. - If PIN 1 and 2 are insulated from ground and the error persists, it means that there is a probable defect in the control unit. P0135 Lambda probe heating - shorted to positive / shorted to negative / open circuit. Error cause Short circuit to positive: excessive voltage at PIN 31 of the control unit connector. Short circuit to negative: lack of insulation from ground on the sensor connector PIN 4. Open circuit: circuit interruption. Troubleshooting Short circuit to positive: - Disconnect the control unit connector and the sensor connector. - Verify that there is no short to battery positive on sensor connector PIN 3 (corresponding to control unit connector PIN 31); in the presence of short circuit, restore the cable harness. ELE SYS - 110
Vespa LXV 125 i.e.
Electrical system
Open circuit: - Disconnect the control unit connector and the sensor connector. - Check the continuity of the cable harness between the sensor connector and control unit connector: control unit PIN 31 - sensor PIN 3. If necessary, restore the cable harness. - Verify continuity of the cabling between the sensor connector and the injection relay: sensor PIN 4 injection relay PIN 87. If necessary, restore the cable harness. - If the cable harness is intact and the error persists, proceed with the following checks. Short circuit to negative: - Disconnect the sensor connector. - Check the sensor connector PIN 4 from ground insulation. If there is no insulation, restore the cable harness. - If PIN 4 is insulated from ground and in the absence of other errors (fuel pump, injector, coil), this means that the control unit is most likely faulty. THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. INJECTOR Function Provide the correct amount of fuel at the correct time. Operation / Operating principle Injector coil is excited for the petrol passage to open. Pinout: 1. Power from relay 2. Ground from control unit ELECTRICAL ERRORS Injector P0201 - short circuit to positive / short circuit to negative / open circuit. Error cause Short circuit to positive: excessive voltage to PIN 34 of the control unit connector. Short circuit to negative: zero voltage to the PIN 1 of the injector connector. Open circuit: circuit interruption. Troubleshooting Short circuit to positive: - Disconnect the injector connector, turn ignition switch to ON and activate the component using the diagnostic tool. - Verify the absence of voltage at the injector connector PIN 2; if present restore the cable harness, otherwise proceed with the following checks. Short circuit to negative: ELE SYS - 111
Electrical system
Vespa LXV 125 i.e.
- Disconnect the injector connector, turn ignition switch to ON and activate the component using the diagnostic tool. - Verify the presence of voltage at the ends of the injector connector; if there is no voltage, restore the cable harness, otherwise proceed with the following checks. Open circuit: - Perform the check of the injector and control unit connectors. - Verify continuity of the cable harness between the control unit connector and the injector connector (control unit PIN 34 - injector PIN 2). If there is no continuity, restore the cable harness.
THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU. FUEL PUMP ELECTRICAL ERRORS Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit. Error cause Short circuit to positive:excessive voltage at PIN 22 of the control unit connector. Short circuit to negative: null voltage at PIN 86 of the injection relay. Open circuit: circuit interruption. Troubleshooting Short circuit to positive: - Disconnect the injection relay, turn the key to ON and activate the relay through the diagnostics instrument. - Verify the presence of voltage between relay connector PIN 86 and 85 toward the cabling. - If no voltage is read, disconnect the control unit and verify insulation from battery positive of the relay PIN 85 (or control unit PIN 22). If necessary, restore the cable harness. Short circuit to negative: - Disconnect the injection relay and the control unit. - Verify ground insulation of the relay connector PIN 86 and 85 toward the cabling: if there is no insulation, restore the cabling. Open circuit: - Disconnect the injection relay and the control unit. - Verify continuity of the cabling between the relay and control unit: Relay PIN 85 - control unit PIN 22. If necessary, restore the cable harness.
ELE SYS - 112
Vespa LXV 125 i.e.
Electrical system
COIL Function Allows generation of the electrical discharge on the spark plug, with an increase of voltage. Pin-out: 1. Power from relay 2. Activation by control unit (control unit side PIN 1) ELECTRICAL ERRORS H.V. Coil P0351 - shorted to positive / open circuit or shorted to negative. Error cause Short circuit to positive: excessive voltage at PIN 1 of the control unit connector. Circuit open or short circuit to negative: interruption of the circuit or null voltage at PIN 1 of the control unit connector. Troubleshooting Short circuit to positive: - Disconnect the coil connector, turn the key to ON and activate the component through the diagnostics instrument. - Verify the presence of voltage on the coil connector PIN 2: if present, restore the cabling, otherwise replace the coil. Open circuit: - Carry out the check procedure of the coil and control unit connectors. - Verify continuity of the cabling between the coil and control unit: Coil PIN 2 - control unit PIN 1. If there is no continuity, restore the cable harness. - Verify, with the key turned ON, the presence of voltage on the coil connector PIN 1. If no voltage is detected, check that the cable harness between the coil and injection relay is not interrupted: Coil PIN 1 - relay PIN 87. - If the above tests provided a positive result, the coil should be replaced. Short circuit to negative: - Disconnect the control unit connector and the coil connector. - Verify the coil connector PIN 2 ground insulation (or control unit connector PIN 1). If necessary, restore the cable harness.
ELE SYS - 113
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Vespa LXV 125 i.e.
Engine from vehicle
Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the head
- Remove the Lambda probe from its support and disconnect it. - Release the lambda probe cable from the brackets on the fan cover.
- Loosen the 2 exhaust fixing screws to the crankcase, then remove the whole exhaust.
- Remove the lambda probe from the manifold.
CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. ENG VE - 115
Engine from vehicle
Vespa LXV 125 i.e.
Removal of the engine from the vehicle

CAUTION
SUPPORT THE VEHICLE ADEQUATELY. - Disconnect the battery. - Remove the side fairings and footrest left and right terminals. - Remove the helmet compartment. - Remove the full silencer unit. - Remove the 3 screws of the rear brake transmission retainer brackets indicated in the picture. - Disconnect the rear brake transmission by unscrewing the adjuster screw. - Disconnect the belt cooling pipe and the swinging arm retaining spring shown in the picture. - Disconnect the ground lead (1) from the engine. - Disconnect the spark plug tube.
- Loosen the clamp indicated in the picture and disconnect the sleeve connecting the air filter to the throttle body.
ENG VE - 116
Vespa LXV 125 i.e.
Engine from vehicle
- Disconnect the two connectors of the magneto flywheel cable harness and slide them from the bottom.
- Remove the ground lead and the positive cable from the starter motor shown in the figure. - Open the clamp indicated and remove the throttle body cables.
- Undo the three screws, with anti-tampering device, that fasten the intake manifold on the head. - Detach from the head the manifold with throttle body and commands and collect the gasket.
- Unscrew the engine pin-swinging arm nut on the right-hand side of the vehicle and slide off the pin on the left hand side - Support the vehicle adequately (with a jack) and remove the shock absorber lower clamping. The engine is now free.
ENG VE - 117
Engine from vehicle
Vespa LXV 125 i.e.
ENG VE - 118
INDEX OF TOPICS
ENGINE
ENG
Engine
Vespa LXV 125 i.e.
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission Transmission cover

- To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes. Using the clutch bell lock wrench, remove the driven pulley axle locking nut and recover the washer. - Remove the cap/dipstick from the engine oil filling hole. - Remove the ten screws. - Remove the transmission cover. If this operation is performed directly on the vehicle, it is necessary to remove the cooling air sleeve and the three air filter housing retainers.
Specific tooling
020423Y Driven pulley lock wrench
Air duct
- Unscrew the Torx screws fixing the air duct bulkhead and remove the bulkhead. - Remove the 3 screws, then take out the duct as well as the filter.
ENG - 120
Vespa LXV 125 i.e.
Engine
Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover. - Use the specific tools to remove the bearing from the crankcase.
CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.
Specific tooling
020376Y Adaptor handle 020375Y 28 x 30 mm adaptor
Refitting the driven pulley shaft bearing

- Heat up the crankcase inside with the hot air gun. - Insert the bearing in its housing, refit the Seeger ring.
N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING.
Specific tooling
020151Y Air heater 020376Y Adaptor handle
ENG - 121
Engine
Vespa LXV 125 i.e.
020357Y 32 x 35-mm Adaptor 020412Y 15-mm guide
Removing the driven pulley

- Remove the spacer, the clutch housing and the whole driven pulley unit.
N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.
Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.
Characteristic
Max. value clutch housing Max. value: 134.5 mm clutch housing standard value Standard value: 134 - 134.2 mm Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment.
ENG - 122
Vespa LXV 125 i.e.
Engine
- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting for dial gauge
Characteristic
clutch housing inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm
Removing the clutch

- Prepare the locking tool for the driven pulley with the pins half-screwed in the tool set to C. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
- Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. Afterwards make the support screw make contact with a minimum force. - Using the specific wrench, inserted 46 mm from the side, remove the clutch central locking nut.
- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring ENG - 123
Engine
Vespa LXV 125 i.e.
020444Y009 wrench 46 x 55
Inspecting the clutch

- Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness 1 mm
Pin retaining collar

- Simultaneously turn and pull the collar manually to remove it.
N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.
Removing the driven half-pulley bearing

- Remove the retainer ring using two flat blade screwdrivers. - Using a hammer and pin, knock the ball bearing out as shown in the figure. - Remove the roller bearing using the specific extractor.
N.B.
ENG - 124
Vespa LXV 125 i.e.
Engine
REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide
Inspecting the driven fixed half-pulley

- Measure the outside diameter of the pulley bushing.
Characteristic
Minimum diameter permitted 40.96 mm Standard diameter 40.965 mm
Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two Orings. - Measure the inside diameter of the mobile halfpulley bushing.
Characteristic
Minimum admissible diameter: 41.08 mm Standard diameter 41.035 mm
ENG - 125
Engine
Vespa LXV 125 i.e.
Refitting the driven half-pulley bearing

- Assemble a new roller bearing using the specific punch, fit the bearing with the label facing outward and insert it completely up to the punch on the halfpulley.
N.B. REST THE HALF-PULLEY ON A WOOD SURFACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020424Y Driven pulley roller casing fitting punch - To assemble the new ball bearing insert it completely down in its housing with the specific punch and finally assemble the Seeger ring.
Specific tooling
020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide
Refitting the driven pulley

- Check that the faying surfaces between the 2 half-pulleys and the belt do not show any signs of wear, scoring and grease. - Insert the new oil seals and O-rings on the movable half-pulley. - Assemble the half-pulley on the ringlet with the appropriate protection sheath. - Make sure the pins and collar are not worn, reassemble the pins and collar. - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.
Specific tooling
ENG - 126
Vespa LXV 125 i.e.
Engine
020263Y Driven pulley assembly sheath
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. -
Inspecting the clutch spring

- Measure the length of the spring when it is relaxed.
Characteristic
Standard length: 106 mm Acceptable limit after use 102.5 mm (4.035 in)
Refitting the clutch

- Check the thickness of the clutch mass friction material. -The masses must not show traces of lubricants; otherwise, check the driven pulley unit.
N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted: 1 mm
ENG - 127
Engine
Vespa LXV 125 i.e.
- Support the driven pulley spring compressor specific tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring No. 11 with the chamfering facing upwards. - Insert the clutch on the adapter ring. - Lubricate the end of the spring that abuts against the torque server closing collar. - Insert the spring with its plastic holder in contact with the clutch. - Insert the drive belt into the pulley unit according to their direction of rotation. - Insert the pulley unit with the belt into the tool. - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Place the tool in the clamp with the control screw on the horizontal axis. - Fully preload the spring. - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt according to its direction of rotation. - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool.
N.B. DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. N.B. FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.
Specific tooling
ENG - 128
Vespa LXV 125 i.e.
Engine
020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55

Nut locking clutch unit on pulley 55 - 60 Nm
Refitting the driven pulley

- Reassemble the clutch housing and spacer.
Drive-belt
- Make sure the drive belt is not damaged and does not show abnormal wear. - Replace as indicated in the scheduled maintenance table.
Removing the driving pulley

- Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the cup washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer.
Specific tooling
020368Y driving pulley lock wrench
ENG - 129
Engine
Vespa LXV 125 i.e.
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling free assembled rollers. - Remove the return rollers plate with the relative guide sliders.
Inspecting the rollers case

- Check that the internal bushing is not abnormally worn and measure inner diameter.
N.B.
DO NOT LUBRICATE OR CLEAN THE BUSHING.
BUSHING ROLLER HOUSING

Specification Maximum allowable diameter Standard diameter Desc./Quantity 26.121 mm 26+0 +0.021 mm
BUSH SLIDE PULLEY

Specification Minimum diameter permitted Standard diameter Desc./Quantity 25.950 mm 26-0.020 -0.041 mm
CVT ROLLERS
Specification Minimum diameter permitted Standard diameter Desc./Quantity 18.5 mm 260.1 mm
ENG - 130
Vespa LXV 125 i.e.
Engine
- Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves.
Refitting the driving pulley

- Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive, belleville washer and nut), spread recommended product on the thread and tighten the nut to the prescribed torque. - Avoid half-pulley rotation using a calliper spanner.
N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
Specific tooling
020368Y driving pulley lock wrench
Loctite 243 Medium-strength threadlock Medium Loctite 243 threadlock

Locking torque 75 to 83
Refitting the transmission cover

- Check that there are 2 alignment dowels and that the sealing gasket for the oil sump on the transmission cover is adequately fitted. - Replace the cover and tighten the 10 screws to the specified torque. - Refit the oil loading cap/bar. - Refit the steel washer and the driven pulley nut. - Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools.
ENG - 131
Engine
Vespa LXV 125 i.e.
- Refit the plastic cover.
Specific tooling
020423Y Driven pulley lock wrench

Transmission cover screws 11 - 13 Driven pulley shaft nut 54 - 60
End gear Removing the hub cover

- Empty the rear hub through the oil drainage tap located inside the hub cover - Remove the brake shoe and relevant spring - Remove the 7 flanged screws as shown in the figure. - Remove the rubber cover and the brake shoes lever sliding unscrewing the relevant retaining screw to reach the rear of the cover - Take off the hub cover and relevant gaskets
Removing the wheel axle

Remove the intermediate gear and the complete hub cover.
ENG - 132
Vespa LXV 125 i.e.
Engine
Removing the hub bearings

- Check the state of the bearings being examined (wear, clearance and noisiness). If faults are detected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
Specific tooling
001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract 15-mm bearings
Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover. - Remove the bearing with the adequate tools adequately supporting the hub cover, as shown in the figure.
Specific tooling
020376Y Adaptor handle 020364Y 25-mm guide With the appropriate tools, remove the oil seal as shown in the figure.
Specific tooling
020376Y Adaptor handle 020359Y 42 x 47-mm Adaptor
Removing the driven pulley shaft bearing

If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven pulley. - Extract the driven pulley shaft from its bearing. - Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to damage the housing, make it come out of the belt transmission side. - Remove the Seeger ring shown in the figure ENG - 133
Engine
Vespa LXV 125 i.e.
With the sectional punch, remove the driven pulley shaft bearing.
Specific tooling
020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20-mm guide
See also
Removing the driven pulley
Inspecting the hub shaft

- Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - If faults are found, replace the damaged components.
Inspecting the hub cover

- Check that the fitting surface is not dented or distorted. - Check the load capacity of the bearings and the brake camshaft. - If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing

- Heat up the parts using the specific heat gun.
Specific tooling
020150Y Air heater mounting 020151Y Air heater - Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
ENG - 134
Vespa LXV 125 i.e.
Engine
- Refit the Seeger ring with the opening facing the bearing as shown in the figure and fit a new oil seal flush with the crankcase.
Refitting the wheel axle bearing

- Heat up the parts using the specific heat gun
Specific tooling
020151Y Air heater 020150Y Air heater mounting -The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide 020360Y 52 x 55-mm Adaptor 020376Y Adaptor handle Assemble the Seeger ring. Assemble the oil seal flush with the internal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub.
Specific tooling
Refitting the hub cover bearings

- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the specific heat gun.
Specific tooling
020150Y Air heater mounting 020151Y Air heater ENG - 135
Engine
Vespa LXV 125 i.e.
- The three 15 mm bearings must be fitted using the appropriate tools.
Refitting the hub bearings

- Insert the cover prepared in the crankcase taking care of inserting the gear of the pulley shaft on the intermediary gear.
Refitting the ub cover

- Fit a new gasket together with the alignment dowels. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Tighten the 7 screws to the prescribed torque.

Flywheel cover Cooling hood

- Remove the fan cover cap acting on the 4 fixing screws.
CAUTION
DURING REMOVAL SLIDE THE CABLE GROMMET FROM THE HOUSING ON THE CAP.
ENG - 136
Vespa LXV 125 i.e.
Engine
- Slide the access flap to the spark plug.
- Remove the two self threading screws, left and right and the lateral left fixing screw on the crankcase base. - Take off the two caps from the thermal group. - Remove the gasket seal of the housing on the head.
Cooling fan
- Remove the fan cover cap. - Remove the cooling fan by acting on the three fixings indicated in the figure.
ENG - 137
Engine
Vespa LXV 125 i.e.
Removing the stator

- Remove the magneto flywheel. - Remove the electric terminal of the minimum oil pressure switch. - Remove the two Pick-Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure. - Remove the stator and its wiring.
Refitting the stator

- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque. - Place the cable harness as shown in the figure.
N.B. THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REFERENCE DOWEL AS SHOWN IN THE DETAIL DRAWING.

Stator screw 3 - 4
Flywheel and starting
ENG - 138
Vespa LXV 125 i.e.
Engine
Removing the starter motor

- Remove the two screws indicated in the figure. - Take the starter motor out of its seat.
Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper spanner. - Remove the nut.
CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS
Specific tooling
020565Y Flywheel lock calliper spanner
- Extract the flywheel with the extractor.
Specific tooling
008564Y Flywheel extractor
Inspecting the flywheel components

- Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.
ENG - 139
Engine
Vespa LXV 125 i.e.
Refitting the flywheel magneto

- Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut to the prescribed torque - Check that the Pick-Up air gap is between 0.34 to 0.76 mm. The air gap cannot be modified when assembling the Pick-Up. Different values result from deformations visible on the Pick-Up mounting.
N.B. A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED

Flywheel nut 52 - 58
Refitting the starter motor

- Fit a new O-ring on the starter and lubricate it. - Fit the starter motor on the crankcase and lock the 2 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
ENG - 140
Vespa LXV 125 i.e.
Engine
Removing the timing system drive

- Remove the parts listed below first: transmission cover, belt driving pulley, oil pump pulley cover and pinion separator washer. - Remove the tappet cover. - Remove the central screw fastener and the automatic valve lifter retaining cover, as shown in the figure. - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counterweight shown in the figure. - Remove the camshaft control pulley with its washer. - Remove the control sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The tensioner pad must be removed from the transmission side. As regards the lower chain guide slider, it may only be removed after the head has been removed.
N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
See also
Removing the driving pulley Transmission cover Removal
ENG - 141
Engine
Vespa LXV 125 i.e.
Removing the cam shaft

- Remove the 2 screws and the camshaft retainer shown in the diagram.
- Remove the cam shaft.
- Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic washer.
N.B. MARK THE ROCKERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INTAKE WITH THE EXHAUST.
Removing the cylinder head

- Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two alignment dowels and the gasket.
N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.
ENG - 142
Vespa LXV 125 i.e.
Engine
Removing the valves

- Using the specific tool fitted with the element shown in the figure, remove the cotters, the caps and the spring between the valves.
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool
- Remove the oil seals with the appropriate tool. - Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
Removing the cylinder - piston assy.

- Remove the chain guide slider. - Remove the cylinder base gasket.
CAUTION TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
- Remove the two retainer rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston.
N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
ENG - 143
Engine
Vespa LXV 125 i.e.
Inspecting the small end

- Measure the internal diameter of the connecting rod small end using an internal micrometer.
N.B. IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".
Characteristic
Connecting rod small end check-up: Maximum diameter 15.030 mm Connecting rod small end check-up: Standard diameter 15+0.015+0.025 mm
Inspecting the wrist pin

- Check the outer diameter of the gudgeon pin.
Characteristic
Standard pin diameter 14.996 - 15 mm Minimum diameter permitted 14.994 mm
- Calculate the piston pin coupling clearance.

N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.
Characteristic
Piston pin bore - standard diameter 15+0.001 +0.006
ENG - 144
Vespa LXV 125 i.e.
Engine
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Measure 36.5 mm from the piston crown's shown in the figure.
N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.
- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out: 0.001 over 0.05 mm - The cylinder rectifying operation should be carried out with a surfacing that respects the original angle. - The cylinder surface roughness should be 0.9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consumption and guarantees optimum performance. - The pistons are oversized due to cylinder rectification and are subdivided into three categories 1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They are also classified into 4 categories A-A, B-B, CC, D-D.
Inspecting the piston

- Carefully clean the seal housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston. ENG - 145
Engine
Vespa LXV 125 i.e.
STANDARD COUPLING CLEARANCE

Name Top piston ring Middle piston ring oil scraper Description Dimensions 0.025 - 0.070 0.015 - 0.060 0.015 - 0.060 Initials Quantity
MAXIMUM ADMITTED CLEARANCE AFTER USE

Name Top piston ring Middle piston ring oil scraper Description Dimensions 0.080 mm 0.070 mm 0.070 mm Initials Quantity
Removing the piston

- Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin retainer ring onto the appropriate tool.
Specific tooling
020430Y Pin lock fitting tool
- With the opening in position indicated on the tool, take retainer ring in the closed position using the punch. - Fit the pin retainer ring using the plug as shown in the figure
N.B. THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
ENG - 146
Vespa LXV 125 i.e.
Engine
Refitting the piston rings

- Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the piston crown. The tapered side of the middle piston ring should always be facing away from the piston crown. - Fit the middle piston ring with the identification letter facing the piston crown. In any case, the step must be facing opposite the piston crown. - Fit the top piston ring with the word 'top' or the reference mark facing the crown of the piston. - Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure. - Lubricate the components with engine oil.
N.B. SO AS TO OBTAIN THE BEST CONFIGURATION THE 2 SEALING RINGS ARE MADE WITH A CONTACT CONICAL CYLINDER SECTION.
Refitting the cylinder

- Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER LINER.
Specific tooling
020426Y Piston fitting fork ENG - 147
Engine
Vespa LXV 125 i.e.
020427Y Piston assembly band
Inspecting the cylinder head

- Using a trued bar check that the cylinder head surface is not worn or distorted. - Check that the camshaft and rocking lever pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn.
Characteristic
Maximum admitted unevenness: Cylinder head check 0.05 mm
STANDARD DIAMETER
Specification Standard diameter Standard diameter Standard diameter Desc./Quantity A 32.5 - 32.525 B 20 - 20.021 C 12 - 12.018
Inspecting the timing system components

- Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft drive pulley, the chain assembly and the sprocket wheel are not worn. - If sings of wear are found, replace the parts. if the chain, pinion or pulley are worn, replace the whole assembly.
ENG - 148
Vespa LXV 125 i.e.
Engine
- Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole unit.
Inspecting the valve sealings

- Measure the width of the sealing surface on the valve seats.
VALVE SEAL SURFACE

Specification Intake valve - seal surface Exhaust valve - seal surface Desc./Quantity 2.4 - 2.8 mm 2.2 - 2.6 mm
Inspecting the valve housings

- Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide. - Take the measurement at three different heights in the rocker arm push direction.
Characteristic
Standard drainage guide diameter 5.012 mm Standard intake guide diameter 5.012 mm
ENG - 149
Engine
Vespa LXV 125 i.e.
- If the width of the impression on the valve seat or the diameter of the valve guide exceed the specified limits, replace the cylinder head. - Check width of the impression on the valve seat V
Characteristic
Wear limits: Max. 1.6 mm.
Inspecting the valves

- Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide.
Characteristic
Minimum diameter admitted - Intake: 4.96 mm Minimum diameter admitted - Exhaust: 4.95 mm Standard clearance - Intake: 0.013 - 0.040 mm Standard clearance - Exhaust: 0.025 - 0.052 mm Maximum clearance admitted- Intake: 0.062 mm Maximum clearance admitted - Exhaust: 0.072 mm - Check that there are no signs of wear on the contact surface with the articulated register terminal. - If the sealing surface on the valves is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.
Characteristic
Standard valve length - Intake: 80.6 mm Valve standard length: Exhaust ENG - 150
Vespa LXV 125 i.e.
Engine
79.6 mm - If no faults are found during the above checks, you can use the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During grinding, keep the cylinder head in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem/guide coupling.
CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
- Insert the valves into the cylinder head. - Test the 2 valves alternatively. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter halves show no signs of abnormal wear. - Check the unloaded springs length.
Characteristic
Valve spring length 33.9 - 34.4 mm
ENG - 151
Engine
Vespa LXV 125 i.e.
Refitting the valves

- Lubricate the valve guides with engine oil. - Place the lower caps of the valve spring on the head. - Use the punch to fit the 2 sealing rings one at a time.
Specific tooling
020306Y Punch for assembling valve seal rings - Fit the valves, the springs and the spring retaining caps. Using the appropriate tool with adapter 11, compress the springs and insert the cotters in their seats.
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool
Inspecting the cam shaft

- Inspect the cam shaft for signs of abnormal wear on the cams.
Characteristic
Standard diameter Bearing A : 32.5 mm -0.025 -0.050 mm Standard diameter Bearing B 20 -0.020 -0.041 mm Minimum admitted diameter bearing A : 32.440 mm Minimum admitted diameter bearing B : 19.950 mm Intake cam height 27.512 mm Exhaust cam height 27.212 mm
ENG - 152
Vespa LXV 125 i.e.
Engine
- Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
Characteristic
Maximum axial clearance admitted 0.42 mm - Check there are no signs of wear on the automatic valve lifter cam, or the end-of stroke roller, or the rubber buffer on the automatic valve-lifter retaining cover. - Check that the valve lifter spring has not yielded. - Replace any defective or worn components.
- Check there are no signs of scoring or wear on the rocking lever bolt. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. - Measure the internal diameter of each rocking lever. -Check that the elastic washer dedicated to the axle clearance of the rocking levers is not worn. In case of failure, replace the damaged components.
Characteristic
Minimum diameter permitted 11.970 mm Maximum diameter allowed 12.030 mm
Refitting the head and timing system components

- Fit the timing chain guide slider. - Insert the head and cylinder alignment dowels, fit the head gasket and the head on the cylinder. ENG - 153
Engine
Vespa LXV 125 i.e.
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.

Locking torque 28 to 30 - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.

- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the tensioner pad by the cylinder head. - Fit the spacer and the screw fastener. - Fit the pin, the exhaust rocking lever, the spring washer and the intake rocking lever. - Lubricate the 2 rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the camshaft in the cylinder head with the cams opposing the rocking levers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed torque.

ENG - 154
Vespa LXV 125 i.e.
Engine
- Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head. - Fit the pulley onto the camshaft. - Assemble the counterweight with the corresponding fixing screw and tighten to the specified torque.

Locking torque 7 to 8.5
-Fit the end-stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft. - Fit the automatic valve lifter return spring. - During this operation the spring must be loaded approximately 180.
N.B. GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE.
- Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed torque.

- Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. ENG - 155
Engine
Vespa LXV 125 i.e.

Locking torque 11 to 13 - Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque.

Locking torque 5 to 6 - Adjust the valve clearance. - Fit the spark plug
Characteristic
Spark plug (125 cm) NGK CR8EB Spark plug (150cm) NGK CR7EB
Electrode gap 0.7 - 0.8 mm

Locking torque 12 to 14 - Assemble the casing sealing gasket on the head. On the fitting direction, use the supplements on the timing side as reference. - Assemble the screw fixing the housing to the crankcase to the specified torque and the 2 selftapping screws joining the half-shells. - Take care that the gasket is well inserted in its housing during the assembly stage. - Place the spark plug access cap.

Locking torque 3 to 4 - Refit the cylinder head cover, tightening the 4 clamping screws to the prescribed torque. - Refit the fan and the housing. - Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as described in the lubrication chapter.
ENG - 156
Vespa LXV 125 i.e.
Engine
- Reassemble the driving pulley, the belt and the transmission cover as described in the transmission chapter.

Crankcase - crankshaft
- Precautionary remove the following units: transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil seals as described in the transmission chapter. - Remove the oil sump, the by-pass, the chain compartment cover and the oil pump as in the lubrication chapter. - Remove the flywheel cover, the fan, the flywheel and the stator as described in the magneto flywheel chapter. - Remove the oil filter and the oil pressure bulb. - Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter. - Remove the 2 retainers indicated in the figure and the starter motor. - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with specific tool dial gauge.
Specific tooling
020262Y Crankcase splitting plate 020335Y Magnetic mounting for dial gauge
Characteristic
Standard clearance 0.15 - 0.40 mm
ENG - 157
Engine
Vespa LXV 125 i.e.
Splitting the crankcase halves

Remove the 11 coupling screws to the crankcase. - Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase. Remove the crankshaft.
CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.
- Remove the coupling gasket of the crankcase halves. - Remove the two screws and the internal shield shown in the diagram.
CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.
- Remove the oil seal on the flywheel side. - Remove the oil filter fitting shown in the diagram
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance 0.20 - 0.50 mm
ENG - 158
Vespa LXV 125 i.e.
Engine
- Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial clearance are not scored and measure the width of the crankshaft between these surfaces, as shown in the diagram.
CAUTION BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard clearance 0.036 - 0.054 mm - If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have any defect, the problem must be due to either excessive wear or wrong machining on the crankcase.
CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING.
Characteristic
Distance between the shoulders 55.67 - 55.85 mm - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart below.
STANDARD DIAMETER
Specification Category 1 Category 2 Desc./Quantity 28.998 - 29.004 28.004 to 29.010
ENG - 159
Engine
Vespa LXV 125 i.e.
Inspecting the crankshaft alignment

To install the crankshaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the crankshaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order. - In case of failures, replace the crankshaft. The big end bushings cannot be replaced. For the same reason, the connecting rod may not be replaced and, when cleaning the crankshaft, be very careful that no impurities get in through the shaft's lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted. - A wrong installation of a cap can seriously affect the bushing lubrication pressure.
N.B. THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft alignment
Characteristic
Off-line maximum admitted A = 0.15 mm
B = 0.01 mm C = 0.01 mm D = 0.10 mm
ENG - 160
Vespa LXV 125 i.e.
Engine
Inspecting the crankcase halves

- Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission side crankcase half, take particular care cleaning the housing and oil ducts for the following components: the oil pump, the oil by-pass valve, the main bushings and the cooling jet on the transmission side (see diagram). - Take particular care, also, that there are no signs wear in the oil by-pass valve housing (see Chapter Lubrication), as this could prevent a good seal in the piston, which regulates the oil pressure.
N.B. THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKS CAN CAUSE A CONSIDERABLE DROP IN THE LUBRICATION PRESSURE FOR MAIN BUSHINGS AND CONNECTING ROD.
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the flywheel side oil seal.
N.B. THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.
- Inspect the mating surfaces on the crankcase halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder and the mating surfaces between the crankcase halves. - Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.
ENG - 161
Engine
Vespa LXV 125 i.e.
- Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and dimensions.
Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels. - The main bushings are comprised of two halfbearings, one with holes and channels for lubrication whereas the other is solid. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder. - To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the figure. - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface.
N.B. TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
Characteristic
Standard driving depth 1.35 - 1.6 - Check the inside diameter of the main bushings in the three directions indicated in the diagram. - Repeat the measurements for the other bushing half. see diagram. - The standard bushing diameter after driving is variable on the basis of a coupling selection. ENG - 162
Vespa LXV 125 i.e.
Engine
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like those for the crankshaft. - The main bushings are subdivided into 3 thickness categories; see the table below:
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification B C E Desc./Quantity Blue Yellow Green
Refitting the crankcase halves

- Fit the internal bulkhead by locking the two screws to the prescribed torque.

- Fit the oil filter joint and tighten it to the prescribed torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, together with the alignment dowels.

ENG - 163
Engine
Vespa LXV 125 i.e.
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half. - Reassemble both crankcase halves. - Fit the 11 screws and tighten them to the prescribed torque.
N.B. WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.

Locking torque 11 to 13 - Lubricate the flywheel oil seal. - Use the appropriate tool to assemble the oil seal. - Fit a new O-ring on the pre-filter and lubricate it. - Insert the pre-filter on the engine with its corresponding cover to the specific torque.
N.B. REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE BETTER SEALING PERFORMANCE. N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEAL.
Specific tooling
020425Y Punch for flywheel-side oil seal

Lubrication
ENG - 164
Vespa LXV 125 i.e.
Engine
Conceptual diagrams
ENG - 165
Engine
Vespa LXV 125 i.e.
Oil pressure check

- After removing the cover protections as described in the "Flywheel" chapter, disconnect the electrical connexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90C, check that the oil pressure is between 0.5 to 1.2 atm. - With the engine idling at 6000 rpm and the oil temperature at ~90C, check that the oil pressure is between 3.2 to 4.2 atm. - Remove the appropriate tools once the measurement is complete, refit the oil pressure switch and washer, tightening it to the prescribed torque and fit the flywheel cover. - If the oil pressure is not within the specified limits, in the following order, check: the oil filter, the oil by-pass valve, the oil pump and the crankshaft seals.
N.B. THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER CONDITION.
Specific tooling
020193Y Oil pressure check gauge
Characteristic
Minimum pressure admitted 3.2 atm.

Locking torque 12 to 14 (also valid for the control connector).
Crankshaft oil seals
ENG - 166
Vespa LXV 125 i.e.
Engine
Removal
- Remove the transmission cover and the complete drive pulley beforehand
- Install the base of the appropriate tool on the oil seal using the screws provided.
- Screw the threaded bar onto the base of the tool and extract the oil seal.
Specific tooling
020622Y Transmission-side oil seal punch
Refitting
- Prepare the new oil seal, lubricating the sealing lip. Warning: do not lubricate the surface for keying onto the engine crankcase.
CAUTION DO NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE.
ENG - 167
Engine
Vespa LXV 125 i.e.
- Preassemble the oil seal with the appropriate tool, positioning the screws - Place the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase
CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. WHEN THE POSITION IS REACHED, DO NOT RETRACT THE OIL SEAL. FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH.
- Orientate the oil seal by inserting the bracket which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as far as it will go.
ENG - 168
Vespa LXV 125 i.e.
Engine
- Use the nut to move the base of the tool until you can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN. Assemble a new oil seal on the flywheel side using the specific tool as shown in the photograph
N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEAL.
Specific tooling
020425Y Punch for flywheel-side oil seal
Oil pump Removal

- Remove the cover of the pump control pulley using the two retainers, as shown in the figure. - Block the rotation of the oil pump control pulley using a screwdriver inserted through one of its two holes.
ENG - 169
Engine
Vespa LXV 125 i.e.
- Remove the central screw with cup washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as shown in the figure. - Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover. - Remove the circlip retaining the innermost rotor. - Remove and wash the rotors thoroughly with petrol and compressed air. - Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the retainer ring.
- Using a feeler gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted 0.12 mm
ENG - 170
Vespa LXV 125 i.e.
Engine
Measure the distance between the outer rotor and the pump body; see figure.
Characteristic
Admissible limit clearance: 0.20 mm
Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure.
Characteristic
Limit values admitted: 0.09 mm
Refitting
- Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the assembly. - Fit the pulley to the pump, the central screw to the specified torque and the cup washer. -Fit the oil pump cover, by tightening the two screws to the prescribed torque.
N.B. FIT THE CUP WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY.

Central screw 12 to 14 Nm Cover screws 0.7 to 0.9
Nm
ENG - 171
Engine
Vespa LXV 125 i.e.
Removing the oil sump

- Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmission chapter. - Drain the oil from the sump as described above. - Remove the 7 screws indicated in the figure and the 2 rear brake transmission fixing brackets. - Remove the spring, the by-pass piston and the gasket shown in the second image.
Inspecting the by-pass valve

- Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length 54.2 mm
ENG - 172
Vespa LXV 125 i.e.
Engine
Refitting the oil sump

- Refit the by-pass piston in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump. - Refit the rear brake transmission mounting brackets and the screws in the reverse order from which they were removed. - Tighten the screws to the prescribed torque. - Refit the driving pulley assembly, the drive belt, the sprocket wheel and the transmission cover, as described in the "Transmission" chapter. - When testing the lubrication system, refer to the "Crankcase and Crankshaft" chapter, regarding lubrication of the connecting rod assembly

ENG - 173
INDEX OF TOPICS
INJECTION
INJEC
Vespa LXV 125 i.e.
Injection
COMPONENT TRANSPOSITION
1 2 3 4 5 6 7 8 9 10 11 Specification Instrument panel Throttle body and electronic injection control unit (MIU) Diagnostics socket connector Fuel pump Engine temperature sensor Fuel injector HV coil Engine speed sensor Lambda probe Injection load relay Battery Desc./Quantity
12V - 10Ah
MIU injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the crankshaft (24-2 teeth) and pick-up sensor. Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further corrections are made according to the following parameters:
INJEC - 175
Injection
Vespa LXV 125 i.e.
- Engine temperature - Intake air temperature - Lambda probe The system implements cold engine idle fuel/air mixture correction with a stepper motor on a by-pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time, thereby ensuring the idle steadiness and the proper combustion. In all conditions of use, mixture preparation is managed by modifying the injector opening time. The fuel system pressure is kept constant in relation to ambient pressure. The fuel system circuit consists of: - Fuel pump - Fuel filter - Injector - Pressure regulator The pump, the filter and the regulator are placed inside the fuel tank on a single support. The injector is connected by a pipe with fast-release fittings. The pressure regulator is located at the beginning of the circuit. The fuel pump is controlled by the MIU; this ensures safety of the vehicle.
The ignition circuit consists of: - HV coil - HV cable. - Shielded cap - MIU control unit - Spark plug The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only in the compression phase) at the same time. The MIU injection-ignition system controls engine functions by means of a pre-set program. Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to reach a service station. Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the control circuits: - Fuel pump - HV coil - Injector
INJEC - 176
Vespa LXV 125 i.e.
Injection
The control unit is provided with a self-diagnosis system connected to an indicator light in the instrument panel.
Failures are detected and restored by the diagnostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine temperature, stop). The diagnostic tester is also required to adjust the idle mixture.
Specific tooling
020922Y Diagnosis Tool The MIU control unit has a decoder for the antitheft immobilizer system. The MIU control unit is connected to a diagnostic LED on the instrument panel, that also carries out the deterrent flashing functions.
Precautions
Troubleshooting tips 1 A MIU failure is more likely to be due to the connections than to the components. Before troubleshooting the MIU system, carry out the following checks: A: Electrical power supply a. Battery voltage b.Burnt fuse c.Remote control switches d.Connectors B: Chassis ground INJEC - 177
Injection
Vespa LXV 125 i.e.
C: Fuel system a. Faulty fuel pump b.Dirty fuel filter D: Ignition system a. Faulty spark plug b.Faulty coil c.Faulty screened cap E: Intake circuit a. Air filter dirty b.Dirty by-pass circuit c.Faulty stepper motor F: Other a. Wrong distribution timing b.Incorrect idle speed carburetion c.Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors. Make sure that all connections have been correctly made. Check the connectors taking into consideration the following point: A check that the terminals are not bent. B check that the connectors have been properly connected. C - Check whether the malfunction can be fixed by shaking the connector slightly. 3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU, install the original control unit again and check if the fault occurs again. 4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instruments that are not suitable might damage the MIU central control unit. Use instruments with definitions over 0.1V and 0.5 W , the precision must be greater than 2%.
1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults. 2. The fuel system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to avoid spraying fuel to your eyes. 3. When fixing electric components, operate with the battery connected only when actually required. 4. When functional checks are performed, check that the battery voltage is over 12V. 5. Before any attempt to start the vehicle, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump. 6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the level. This will ensure the pump will be covered by fuel. INJEC - 178
Vespa LXV 125 i.e.
Injection
7. When washing the vehicle, be careful with the electric components and cable harnesses. 8. When an ignition problem is detected, start the checks from the battery and the injection system connections. 9. Before disconnecting the MIU ECU connector, perform the following steps in the order shown: - Set the switch to OFF - Disconnect the battery Failure to respect this norm may damage the control unit. 10. Do not invert the poles when fitting the battery. 11. To avoid causing any damage, disconnect and reconnect the MIU system connectors only if required. Before reconnecting, check that the connectors are dry. 12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not take measurements not specifically foreseen by the manual. 13. At the end of every check performed with the diagnostic tester, remember to protect the system connector with its cap. Failure to observe this precaution may damage the MIU control unit. 14. Before reconnecting the quick couplers of the power supply system, check that the terminals are perfectly clean.
Terminals setup
1. Injection warning light 2. incomplete 3. incomplete 4. (-) lambda probe 5. (+) live battery 6. (+) battery 7. Immobilizer aerial 8. incomplete
INJEC - 179
Injection
Vespa LXV 125 i.e.
9. Engine temperature sensor 10.incomplete 11.(+) lambda probe 12.Engine stop switch 13.(+) engine speed sensor 14.(-) fuel injector 15.(-) engine speed sensor 16.Diagnostics output 17.Immobilizer LED 18.Pin short-circuited with pin 26 19.(-) low beam automatic ignition 20.(-) injection load remote control 21.Lambda probe 22.(-) HV coil 23.incomplete 24.Start up enabling 25.incomplete 26.Ground lead
ELECTRONIC CONTROL UNIT CONNECTOR 1. H.V. COIL (Pink-Black) 2. Not connected 3. Not connected 4. Ground (Green-Black) 5. Not connected 6. Key powered(Red-White) 7. Ground No. 1 (Black) 8. Not connected 9. Battery-powered (Grey-Black) 10. Start-up enabling switch (Orange-Blue) INJEC - 180
Vespa LXV 125 i.e.
Injection
11. Lambda probe positive (Sky blue-Black) 12. Lambda probe negative (White-Green) 13. Water temperature sensor (Sky blue-Green) 14. Immobilizer aerial (Orange-White) 15. Not connected 16. K serial line (Purple-White) 17. Immobilizer (Red-Green) 18. Not connected 19. Side stand (Grey-Green) 20. Engine speed sensor negative (Brown) 21. Not connected 22. Injection load relay (Black-Purple) 23. Not connected 24. Not connected 25. Injection warning light (Brown-Black) 26. Not connected 27. Not connected 28. Not connected 29. Engine speed sensor positive (Red) 30. Not connected 31. Lambda probe heater (Green-Yellow) 32. Not connected 33. Low beam lights automatic ignition enabling (White-Black) 34. Fuel injector (Red-Yellow)
INJEC - 181
Injection
Vespa LXV 125 i.e.
EMS circuit diagram
1. Battery 12V - 10 Ah 2. Engine speed sensor 3. Engine temperature sensor 4. Immobilizer aerial 5. Stop buttons 6. Fuse No. 1 of 20A 7. Key switch contacts 8. Fuse No. 3 of 7.5A 9. Fuse No. 6; 15A 10.Engine control telltale light 11.Fuse No. 2; 7.5A 12.Injection load remote controls 13.Fuse No. 4; 7.5A 14.Starter button 15.Starter relay 16.Diagnostics socket output 17.Starter motor 18."IMMOBILIZER" led 19.Fuel pump 20.HV coil
INJEC - 182
Vespa LXV 125 i.e.
Injection
21.Injector 22.Lambda probe 23.Low beam light solenoid 24.High-beam light solenoid 25.Light switch 26.Electronic control unit THE FOLLOWING INFORMATION REFER TO THE VERSION EQUIPPED WITH MIU G3 ECU.
Key: 13. engine stop switch 14. Fuses No. 3- 7.5A; No. 6- 15A 15. High-beam light solenoid 16. Low beam light solenoid 19. Ignition switch contacts 20. Fuse No.2 - 7.5A 23. Starter remote control switch 25. Fuse No.1 - 20A 26. 12v-10Ah battery 30. Injection load relay 33. Lambda probe INJEC - 183
Injection
Vespa LXV 125 i.e.
34. Engine speed sensor 35. HV coil 36. Fuel injector 37. Engine temperature sensor 38. Fuel system pump 39. Diagnostics socket 40. Injection electronic control unit 41. Immobilizer antenna 42. Bulb for engine control telltale light 48. Immobilizer LED warning light
Troubleshooting procedure Engine does not start

ENGINE DOES NOT START IF ONLY PULLED
Possible Cause Immobiliser enabling signal Operation System not encoded System not efficient, repair according to the indications of the self-diagnosis Pump relay HV coil Injector Revolution timing sensor Fuel in the tank Fuel pump activation Fuel pressure (low) Injector capacity (low) Shielded spark plug cap HV coil (secondary insulation) Engine temperature Distribution timing - injection ignition Intake air temperature End of compression pressure
Presence of faults detected by the self diagnosis
Fuel system
Power to the spark plug Parameter reliability
End of compression pressure
Starting difficulties
ENGINE STARTER PROBLEMS
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Starter motor and solenoid Battery Ground connections End of compression pressure Spark plug Shielded cap HV coil Speed-timing sensor Ignition advance
Start-up speed
End of compression pressure Power to the spark plug
INJEC - 184
Vespa LXV 125 i.e.
Injection
Possible Cause Fuel system
Correctness of the parameters
Operation Fuel pressure (low) Injector capacity (low) Injector sealing (poor) Engine temperature Stepper throttle valve position intake air temperature (steps and actual opening) Cleaning the throttle valve, air filter efficiency
Engine stops at idle

ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Spark plug Ignition timing Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Air filter Diffuser and throttle valve Stepper Intake manifold - head Throttle body - manifold Air cleaner joint Filter box Fuel pump Pressure regulator Fuel filter Injector capacity
Ignition efficiency Correctness of the parameters
Intake system cleaning
Intake system sealing (infiltrations)
Fuel system (low pressure)
Engine does not rev down

ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Ignition timing Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake manifold - head Throttle body - manifold Air cleaner joint Filter box Fuel pump Pressure regulator Fuel filter Injector capacity
Ignition efficiency Correctness of the parameters
INJEC - 185
Injection
Vespa LXV 125 i.e.
Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATING
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Lambda sensor Throttle valve position sensor Stepper Engine temperature sensor Intake air temperature sensor Intake manifold - head Throttle body - manifold Air cleaner joint Filter box Fuel pump Pressure regulator Fuel filter Injector capacity Manifold - head Manifold - silencer silencer welding
Correctness of the parameters
Exhaust system sealing (infiltrations)
Engine revs irregularly

ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN
Possible Cause Intake system cleaning Operation Air filter Diffuser and throttle valve Stepper Air cleaner joint Filter box Spark plug wear check Throttle valve position signal Engine temperature signal Intake air temperature indicator Ignition advance TPS reset successful Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Lambda sensor
Intake system sealing Ignition system Parameter reliability
TPS reset successful Presence of faults detected by the self diagnosis
Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORMANCE ON PICKUP
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature
INJEC - 186
Vespa LXV 125 i.e.
Injection
Possible Cause Spark plug power supply
Intake system
Parameter reliability
Fuel system
Operation Lambda sensor Spark plug Shielded cap HV cable HV coil Air filter Filter box (sealing) Air cleaner joint (sealing) Throttle valve position signal Engine temperature signal Intake air temperature indicator Ignition advance Fuel level in the tank Fuel pressure Fuel filter Injector capacity
Engine knocking
PRESENCE OF KNOCKING (COMBUSTION SHOCKS)
Possible Cause Presence of faults detected by the self diagnosis Operation Pump relay HV coil Injector Revolution timing sensor Air temperature Engine temperature Lambda sensor Spark plug Throttle valve position signal Engine temperature signal Intake air temperature indicator Ignition advance Air cleaner joint Filter box TPS reset successful Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness
Ignition efficiency Parameter reliability
Intake system sealing TPS reset successful Fuel system
Selection of the cylinder base gasket thickness
Fuel supply system

The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector and the fuel delivery pipes. The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through the filter. The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 187
Injection
Vespa LXV 125 i.e.
Removing the injector

- Remove the helmet compartment. - Remove the connector from the injector. - Remove the quick release of the petrol delivery pipes.
INJEC - 188
Vespa LXV 125 i.e.
Injection
- Undo the fixing screws and slide the injector from the manifold being careful not to damage the sealing OR gasket.
CAUTION DO NOT DISASSEMBLE THE INJECTOR COMPONENTS.
Refitting the injector

For refitting, perform the removal operations in reverse order and lubricate the sealing OR gasket with grease for internal application before fitting the injector on the manifold.
INJEC - 189
Injection
Vespa LXV 125 i.e.
Removing the butterfly valve

- Remove the helmet compartment. - Remove the fuel piping clamping screw indicated in the figure.
- Remove the fast-release fitting from the injector. - Remove the injector connector. - Remove the three screws with anti-tampering device fixing the manifold to the head and the clip fixing the throttle body to the manifold.
Remove the MIU ECU connector.
- Remove the fastening clamp of the air cleaner joint to the air filter body.
INJEC - 190
Vespa LXV 125 i.e.
Injection
- Remove the mounting bracket of the throttle control cables undoing the two fixing screws. - Release the cable ends of the throttle body pulley. - Remove the throttle body with air cleaner joint, manifold and injector.
Refitting the butterfly valve

For refitting, perform the steps in the reverse direction to disassembly taking care to orientate the air cleaner joint by inserting it in the reference tooth on the throttle body as shown in the picture. - To adjust the throttle control cables, act on the specific adjuster screws.
INJEC - 191
Injection
Vespa LXV 125 i.e.
Pump supply circuit
1. 12V - 10Ah Battery 2. Fuse No. 6; 15A 3. Fuse No. 1; 20A 4. Key switch contacts 5. 7.5A fuse No. 2
INJEC - 192
Vespa LXV 125 i.e.
Injection
6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Lambda probe When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied. ELECTRICAL DATA Pump winding resistance ~ 1.5 Ohm Input current during normal functioning 1.4 to 1.8 A input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel pressure) Check efficiency of the fuse No. 6 of 15A injection loads, next to the battery.
Check efficiency of fuse No. 2 of 7.5A, a 7,5A live control unit power supply, after removing the central cover of the shield.
INJEC - 193
Injection
Vespa LXV 125 i.e.
Check efficiency of the injection load relay, that can be reached by removing the central cover of the shield: check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the relay.
Check the power supply line of the injection load solenoid energising coil: after switching to "ON", make sure there is battery voltage, for 2 seconds, between the Red-White cable and Black-Purple cable of the solenoid base. If there is not, check the continuity of the Red-White cable between the fuse box and the solenoid base and of the BlackPurple cable between the pin 20 of the control unit and the solenoid base.
N.B. CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (RELAYS, CONTROL UNIT, FUSES ETC.).
INJEC - 194
Vespa LXV 125 i.e.
Injection
INJEC - 195
Injection
Vespa LXV 125 i.e.
Check the presence of fixed voltage between the grey/black cable of the remote control base and ground. If there is not, check the continuity of the Grey/Black cable between the fuse box (No. 6, 15 A) and the remote control base.
pump circuit6
Check, on switching to "ON", that there is battery voltage, for about two seconds, to the Black-Green cable of the pump connector and ground with pump connector disconnected. Otherwise, check the continuity of the Black-Green cable between the pump connector and the remote control base. Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable, system side, and the ground. If, when switching to "ON", the pump continues to turn after two seconds of activation, check, with the control unit disconnected and the injection load reINJEC - 196
Vespa LXV 125 i.e.
Injection
mote control disconnected, that the Black-Purple cable (pin 20 on the interface wiring) is insulated from the ground.
Specific tooling
020331Y Digital multimeter
INJEC - 197
Injection
Vespa LXV 125 i.e.
1. Battery 12V- 6 Ah 2. Fuse No. 6; 15A 3. Fuse No. 1; 20A 4. Ignition switch contacts 5. 7.5A fuse No. 2 6. Injection load relay 7. Fuel pump INJEC - 198
Vespa LXV 125 i.e.
Injection
8. HV coil 9. Fuel injector 10.Lambda probe When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied. ELECTRICAL DATA Pump winding resistance ~ 1.5 Ohm Input current during normal functioning 1.4 to 1.8 A input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel pressure) Check efficiency of the fuse No. 6 of 15A injection loads, next to the battery.
Check efficiency of fuse No. 2 of 7.5A, live control unit power supply, after removing the central cover of the shield.
INJEC - 199
Injection
Vespa LXV 125 i.e.
Check the power supply line of the injection load relay energising coil: after switching to "ON", make sure there is battery voltage, for 2 seconds, between the Red-White cable and Black-Purple cable of the relay base. If there is not, check the continuity of the Red-White cable between the fuse box and the relay base and of the Black-Purple cable between the pin 22 of the control unit and the relay base.
INJEC - 200
Vespa LXV 125 i.e.
Injection
Check the presence of fixed voltage between the grey/black cable of the relay base and ground. Otherwise, check the continuity of the grey-black cable between the fuse-box (No. 6, 15 A) and the relay base.
INJEC - 201
Injection
Vespa LXV 125 i.e.
Check, on switching to "ON", that there is battery voltage, for about two seconds, to the Black-Green cable of the pump connector and ground with pump connector disconnected. Otherwise, check the continuity of the Black-Green cable between the pump connector and the relay base. Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable, system side, and the ground. If, when switching to "ON", the pump continues to turn after two seconds of activation, check, with the control unit disconnected and the injection load remote control disconnected, that the Black-Purple cable (pin 22 on the control unit) is insulated from the ground.
Specific tooling
020331Y Digital multimeter
Circuit leak test

Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge. Check during regular operation by placing the appropriate tool between the pump and the injector. With the battery voltage > 12 V check that the fuel pressure is 2.5 BAR and that the input current is 1.4 to 1.8 A.
With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool. Make a graded burette available with a flow rate of approximately 1 L. Rotate the pump using the active diagnosis of the palm top computer. Using a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 bar. Check that within 15 seconds the pump has a flow rate of approx. 110 cm.
Specific tooling
020480Y Petrol pressure check kit
INJEC - 202
Vespa LXV 125 i.e.
Injection
Fuel filter check

After removing from the tank, disconnect the electric pump terminals.
Remove the screw shown in the picture
Remove the clip fixing the piping to the filter shown in the picture
Separate the lower part of the pump mounting as shown in the picture.
INJEC - 203
Injection
Vespa LXV 125 i.e.
Remove the filter from the pump mounting
INJEC - 204
Vespa LXV 125 i.e.
Injection
Inspecting the injector circuit
1. 12V - 10Ah Battery 2. Fuse No. 6; 15A 3. Fuse No. 1; 20A 4. Key switch contacts 5. 7.5A fuse No. 2
INJEC - 205
Injection
Vespa LXV 125 i.e.
6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Lambda probe Check the resistance at the injector ends: 14.5 5% Ohm Check efficiency of the fuse No. 6 of 15A injection loads, next to the battery.
INJEC - 206
Vespa LXV 125 i.e.
Injection
INJEC - 207
Injection
Vespa LXV 125 i.e.
INJEC - 208
Vespa LXV 125 i.e.
Injection
With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable between pin 14 of the interface wiring and the injector connector
INJEC - 209
Injection
Vespa LXV 125 i.e.
Switch to ON and check if there is voltage, with injector disconnected and control unit connected, between the Black-Green cable of the injector connector and the ground lead
With injector disconnected and the injector load relay disconnected, check the continuity of the Black-Green cable between the injector connector and relay base.
INJEC - 210
Vespa LXV 125 i.e.
Injection
Injection
Vespa LXV 125 i.e.
8. HV coil 9. Fuel injector 10.Lambda probe Check the resistance at the injector ends: 14.5 5% Ohm Check efficiency of the fuse No. 6 of 15A injection loads, next to the battery.
INJEC - 212
Vespa LXV 125 i.e.
Injection
INJEC - 213
Injection
Vespa LXV 125 i.e.
With the control unit and the injector disconnected, check if there is continuity in the Red-Yellow cable between pin 34 of the control unit connector and the injector connector.
INJEC - 214
Vespa LXV 125 i.e.
Injection
Switch to ON and check if there is voltage, with injector disconnected and control unit connected, between the Black-Green cable of the injector connector and the ground lead
With injector disconnected and the injector load relay disconnected, check the continuity of the Black-Green cable between the injector connector and relay base.
Inspecting the injector hydraulics

To carry out the injector check, remove the intake manifold by removing the three screws, with antitampering device, fixing the head and loosening the clamp connecting the throttle body to the manifold. Release the injector fuel delivery pipe from the bracket on the throttle body.
Install the appropriate tool for checking fuel pressure and position the manifold over a container graduated by at least 100 cm. Connect the injector with the cable making up part of the supply for the injection tester. Connect the clamps of the cable to an auxiliary battery. Activate the fuel pump with the active diagnosis. Check that, within fifteen seconds, approximately 40 cm of fuel is dispensed with an adjustment pressure of approximately 2.5 BAR.
INJEC - 215
Injection
Vespa LXV 125 i.e.
Specific tooling
020480Y Petrol pressure check kit
Proceed with the injector seal test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector. Slight oozing is normal. Value limit = 1 drop per minute
Tachometer
INJEC - 216
Vespa LXV 125 i.e.
Injection
With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approximately 20
Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2.8 V
With the interface cable harness disconnected from the control unit, check continuity between pin 13 and the red cable of the engine speed sensor connector and between pin 15 and the brown cable of the engine speed sensor connector
With the interface wiring and rpm sensor connector disconnected from the control unit, check that the Red and Brown cables (pin 13 - 15) are isolated from each other and insulated from the ground.
Specific tooling
INJEC - 217
Injection
Vespa LXV 125 i.e.
Con cablaggio scollegato dalla centralina e collegato all'impianto verificare che la resistenza del sensore tra i pin 20 - 29 sia compresa tra 100 e 150 ohm ad una temperatura motore di circa 20. Disconnect the fuel pipe connector. Start up the engine and wait for it to stop. With the wiring connected to the control unit and system try to start up the engine and check that the voltage between pins 29 and 20 is around 2.8 V - Check the continuity between pin 29 of the injection control unit and the red cable of the engine speed sensor. - Check the continuity between pin 20 of the injection control unit and the brown cable of the engine speed sensor. - Check that the pins 20 and 29 of the control unit are insulated from each other and insulated from the ground.
Specific tooling
020331Y Digital multimeter INJEC - 218
Vespa LXV 125 i.e.
Injection
HT coil
1. 12V - 10Ah Battery 2. Fuse No. 6; 15A 3. Fuse No. 1; 20A 4. Key switch contacts 5. 7.5A fuse No. 2 INJEC - 219
Injection
Vespa LXV 125 i.e.
6. Injection load remote control 7. Fuel pump 8. HV coil 9. Fuel injector 10.Lambda probe The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two significant parameters: - Ignition advance This is optimised at the moment in accordance with the engine revs, engine load, temperature and environmental pressure. With the engine at idle, the ignition advance is optimised to stabilise the speed at 1450 50 rpm. - Magnetisation time The coil magnetisation time is controlled by the control unit. The ignition power is increased during the engine start-up phase. The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression phase.
Specific tooling
020331Y Digital multimeter Check efficiency of the fuse No. 6 of 15A injection loads, next to the battery.
INJEC - 220
Vespa LXV 125 i.e.
Injection
Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to ON.
Check the resistance of primary coil between pin 22 of the interface wiring and the Black-Green cable of the injection load remote control base, that can be reached by removing the shield central cover, with the control unit disconnected and the remote control disconnected. Resistance of the primary = 0.5 8% Ohm
INJEC - 221
Injection
Vespa LXV 125 i.e.
Check the efficiency of the injection load relay. Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the relay.
INJEC - 222
Vespa LXV 125 i.e.
Injection
INJEC - 223
Injection
Vespa LXV 125 i.e.
INJEC - 224
Vespa LXV 125 i.e.
Injection
Injection
Vespa LXV 125 i.e.
8. HV coil 9. Fuel injector 10.Lambda probe The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two significant parameters: - Ignition advance This is optimised at the moment in accordance with the engine revs, engine load, temperature and environmental pressure. With the engine at idle, the ignition advance is optimised to stabilise the speed at 1450 50 rpm. - Magnetisation time The coil magnetisation time is controlled by the control unit. The ignition power is increased during the engine start-up phase. The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression phase.
Specific tooling
020331Y Digital multimeter Check efficiency of the fuse No. 6 of 15A injection loads, next to the battery.
Check that there is voltage, for about two seconds, between red/black cable of the coil connector and ground switching in ON.
INJEC - 226
Vespa LXV 125 i.e.
Injection
Check the resistance of the coil primary between the pin 1 of the control unit and the black/green cable of the injection load relay, that can be reached by removing the central cover of the shield, with the control unit and relay disconnected. Resistance of the primary = 0.5 8% Ohm
INJEC - 227
Injection
Vespa LXV 125 i.e.
INJEC - 228
Vespa LXV 125 i.e.
Injection
Zeroing the throttle

Resetting the throttle valve position signal (TPS reset) The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated. Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre-set reference conditions. Pre-calibration ensures optimal air flow to control idling. This regulation must not be tampered with in any way whatsoever. The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance. The throttle body after the pre-calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself. The valve position sensor can also assume various fitting positions. For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another. To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to match the throttle body with the control unit following the procedure known as TPS resetting. With this operation we inform the control unit, as the starting point, of the mV value corresponding to the pre-calibrated position. To reset, proceed as follows.
INJEC - 229
Injection
Vespa LXV 125 i.e.
Connect the diagnostic tester. Switch to ON. Select the functions of the diagnostic tester on TPS RESET.
Specific tooling
020922Y Diagnosis Tool
Make sure that the throttle valve with the control is supporting the stop screw.
Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
INJEC - 230
Vespa LXV 125 i.e.
Injection
Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced.
N.B.
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Lambda probe
SIGNAL CONTROL
1. Lambda probe
INJEC - 231
Injection
Vespa LXV 125 i.e.
Install the electronic control unit interface wiring. Start the engine and let it warm up. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Place the tips of the multimeter between pins 4 (-) and 11 (+)
With the engine running at idle speed, check that the voltage oscillates between 0V and 1V With the throttle valve completely open, the voltage is approx. 1V. During the closing phase, the voltage is approx. 0V. If the voltage remains constant, the sensor may be damaged. Remove the sensor and check that there are no oil or carbon deposits inside it..
LAMBDA PROBE
1 Specification Lambda probe Desc./Quantity
INJEC - 232
Vespa LXV 125 i.e.
Injection
Specification Injection ECU
Desc./Quantity
PIN RELATIONSHIP
PIN 12 PIN 11 Component Lambda probe Reference value ~ 0V with throttle valve closed; ~ 1V with throttle valve fully opened
With the engine running at idle speed, check that the voltage oscillates between 0V and 1V With the throttle valve completely open, the voltage is approx. 1V. During the closing phase, the voltage is approx. 0V. If the voltage remains constant, the sensor may be damaged. Remove the sensor and check that there are no oil or carbon deposits inside it..
INJEC - 233
INDEX OF TOPICS
SUSPENSIONS
SUSP
Vespa LXV 125 i.e.
Suspensions
Front suspension This section is dedicated to operations that can be carried out on the suspensions.
Front Removing the front wheel

- Support the vehicle adequately. - Loosen the five screws fixing the wheel to the hub.
Front wheel hub overhaul

- Support the vehicle adequately. - Remove the front wheel. - Remove the front brake calliper. - Remove the cotter pin and remove the cap.
- Unscrew the nut fixing the front wheel hub.
SUSP - 235
Suspensions
Vespa LXV 125 i.e.
- Remove the wheel hub.
- Remove the ball bearing check Seeger ring indicated in the picture
Extract the ball bearing using the specific tool
Specific tooling
001467Y014 Calliper to extract 15-mm bearings 001467Y017 Bell for bearings, OD 39 mm
- Remove the oil seal on the roller bearing side using a screwdriver.
SUSP - 236
Vespa LXV 125 i.e.
Suspensions
- Remove the roller bearing using the specific tool
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20-mm guide
- Heat the roller bearing seat with a heat gun - Use the specific tool to introduce and push the bearing until it stops, with the shielded side facing out - Refit the ball bearing check Seeger ring
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020357Y 32 x 35-mm Adaptor 020412Y 15-mm guide - Use the specific tool to fit and push the roller casing until it stops - Refit the oil seal on the roller bearing side - Lubricate the area between the roller bearing and the ball bearing
Specific tooling
020038Y Punch
AGIP GREASE MU3 Yellow-brown, lithiumbase, medium-fibre multipurpose grease. ISO L-X-BCHA 3 - DIN 51 825 K3K -20 - To refit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torque.

Front wheel axle nut 75 to 90
SUSP - 237
Suspensions
Vespa LXV 125 i.e.
Refitting the front wheel

- Upon refitting, tighten the five screws to the prescribed torque.

Wheel rim screws 20 to 25
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 removal operations but in the reverse order, observing the prescribed tightening torque.

Handlebar lock nut 45 to 50
Steering column
SUSP - 238
Vespa LXV 125 i.e.
Suspensions
Removal
After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork.
Specific tooling
020055Y Wrench for steering tube ring nut
Overhaul
Servicing the front suspension-steering assembly, described below, deals mainly with replacing parts (pin- NADELLA roller bushings - sealing rings unit and dust gaiter) which connect the steering tube to the front wheel holder swinging hub.
N.B. BEFORE PROCEEDING WITH THE DESCRIBED SERVICE, CHECK THAT THE STEERING TUBE AND THE WHEEL HOLDER HUB ARE IN EXCELLENT CONDITIONS: ONLY THEN IS THE SERVICE JUSTIFIABLE. MOREOVER, REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE WHEN DEFORMED.
a = 12 Punch b = Sharp-edged end Use a suitable punch with the dimensions indicated on the figure; hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end. Repeat the operation for the second washer using the punch on the side opposite to the one shown in the figure. Use the tool fitted with part 1 as shown in the figure and move the tool handgrip until the pin and the NADELLA are simultaneously ejected in the direction opposite the tool thrusting force. After removing the pin and the first NADELLA, the swinging hub gets detached from the steering tube.
SUSP - 239
Suspensions
Vespa LXV 125 i.e.
To remove the second NADELLA, use the tool fitted with part 2 instead of part 1, on the side opposite the one shown in the figure.
N.B. DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE, THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED. UPON REFITTING, IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN, NEW SEALING RINGS AND DUST GAITER.
Specific tooling
020021Y Front suspension service tool Connect the swinging hub to the steering tube with the guiding pin. - Use the tool fitted with part 3 on the stem and part 4. Lubricate the pin with recommended grease and insert it temporarily on the swinging hub, move the tool handgrip until part 3 is fully inserted on the steering tube. After fitting the pin, insert the two spacers, slightly hitting them with the mallet.
N.B. BEFORE PROCEEDING WITH THE DESCRIBED FITTING, PLACE THE TWO DUST GAITER RINGS ON THE SWINGING HUB AS SHOWN IN THE FIGURE.
Specific tooling
020021Y Front suspension service tool
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide. Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time. - Remove the tool and the part 5 (guide), which has been partially ejected during the previous pin fitting phase, and leave part 4 always fitted. - Replace part 3 with part 16 (on the stem). - By moving the tool handgrip, push the wedging washer - roller bushing - seal ring unit, placing part 16 until it stops on the swinging hub.
SUSP - 240
Vespa LXV 125 i.e.
Suspensions
- Repeat the above operation using the tool with part 16 and part 22, instead of part 4, always fitted to the stem, on the side opposite that indicated in the figure to fit the second wedging washer - roller bushing - sealing ring unit.
WARNING BEFORE PROCEEDING WITH THE DESCRIBED PRE-FITTING, DIP THE SEALING RINGS IN MINERAL OIL AND THE "NADELLA" ROLLER BUSHINGS (PREVIOUSLY WASHED IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMINATE THE ANTIRUST PROTECTION), HALF-FILLED WITH GREASE.
Specific tooling
020021Y Front suspension service tool
AGIP GREASE MU3 Yellow-brown, lithiumbase, medium-fibre multipurpose grease. ISO L-X-BCHA 3 - DIN 51 825 K3K -20 - Use the tool fitted with part 20 on its stem and part 21 on the tool base as shown in the figure. - By moving the tool handgrip, push the two NADELLA bushings until their internal bottoms make contact with the pin end. - Use the tool fitted with parts 3 and 4 to fit the pin, and press moving the tool handgrip, until wedging the washers on the swinging hub. - Now, remove the two spacers (parts 17 and 16) and, once the space between the NADELLAs steering tube and swinging hub - has been fully filled with grease, move the dust gaiter rings until they are placed in that space. - By wedging the washers as described above, the front suspension unit refitting stage is finished.
AGIP GREASE MU3 Yellow-brown, lithiumbase, medium-fibre multipurpose grease. ISO L-X-BCHA 3 - DIN 51 825 K3K -20
Refitting
CAUTION
USE NEW ROLLER CASINGS, PIN, SEALING RINGS AND DUST GUARDS FOR REFITTING. SUSP - 241
Suspensions
Vespa LXV 125 i.e.
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 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease. TL 9150 066, symbol NATO G 460

Steering lower ring nut 8 10 Steering upper ring nut 35 to 40
Front shock absorber
SUSP - 242
Vespa LXV 125 i.e.
Suspensions
Removal
- Support the vehicle adequately. - Remove the wheel hub. - Loosen the shock absorber lower clamps and remove the brake calliper shock absorber mounting.
- Loosen the screws fixing the front brake pipe retainer clamp and the odometer cable in order to reach the upper clamps.
- Unscrew the upper fixing nuts.
- Remove the front shock absorber.
SUSP - 243
Suspensions
Vespa LXV 125 i.e.
Refitting
To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.

shock absorber lower clamping 20 - 27 shock absorber upper clamp 20 to 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
- 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

Shock absorber lower clamping 20 to 27
SUSP - 244
Vespa LXV 125 i.e.
Suspensions
Overhaul
- The bracket for the shock absorber -calliper attachment has two roller bearings separated one from the other as shown in the photograph
- Remove the two roller bearings from the bracket with the specific tool operating on the shock absorber attachment side as shown in the photograph
Specific tooling
020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020365Y 22 mm guide - Remove the oil seal on the wheel hub side with the screwdriver as shown in the photograph
- Suitably hold the brake calliper - shock absorber attachment bracket - Fit a new oil seal and move it until it stops using the specific tool
Specific tooling
SUSP - 245
Suspensions
Vespa LXV 125 i.e.
- Assemble a new roller bearing on the shock absorber side and move it until it stops using the specific tool
Specific tooling
020036Y Punch
- Suitably hold the brake calliper - shock absorber attachment bracket - Assemble a new roller bearing on the wheel hub side and move it until it stops using the specific tool
Specific tooling
020037Y Punch
Refitting
- Refit the parts in reverse order of the removal operation.
CAUTION BEFORE CARRYING OUT REFITTING OPERATIONS IN THE AREAS MARKED WITH AN ASTERISK, LUBRICATE THEM WITH THE RECOMMENDED PRODUCT
Specific tooling
020036Y Punch 020037Y Punch
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease. TL 9150 066, NATO G 460 symbol
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.
SUSP - 246
Vespa LXV 125 i.e.
Suspensions
TO REMOVE THE LOWER SEAT OF THE LOWER STEERING BEARING JUST USE A SCREWDRIVER AS A LEVER BETWEEN THE SEATING AND THE SLEEVE.
Specific tooling
020004Y Punch for removing steering bearings from headstock - Remove the fifth wheel fitting and the dust gaiter on the steering bearing as shown in figure, using the specific tool. Proceed giving a few taps with the mallet.
Specific tooling
020004Y Punch for removing steering bearings from headstock
- Refit the fifth wheel fitting and the dust gaiter on the steering bearing until they stop, using the specific tool.
Specific tooling
006029Y Punch for fitting steering bearing seat on steering tube
Rear Removing the rear wheel

- Remove the silencer. - Remove the cotter pin and remove the cap.
SUSP - 247
Suspensions
Vespa LXV 125 i.e.
- Unscrew the nut fixing the wheel axle and collect the washer.
Refitting the rear wheel

- To refit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torque.

Locking torque 137 to 152 Nm
Swing-arm
SUSP - 248
Vespa LXV 125 i.e.
Suspensions
Removal
- Support the vehicle adequately. - Remove the central tunnel inspection door. - To remove the upper clamp from the chassis, proceed as follows: - Unscrew the pin and collect the washer.
- Remove the cap from the lower part.
- Collect the lower fixing nut and collect the washer.
- Working on both sides, remove the cover caps.
SUSP - 249
Suspensions
Vespa LXV 125 i.e.
- Working on the right side, unscrew the side fixing nut to the chassis and collect the washer.
- Working on the left side, remove the pin.
- Remove the spoiler terminal from both sides. - Working on the right side, unscrew the fixing nut.
- Working on the left side, release the pin from the spring shown.
SUSP - 250
Vespa LXV 125 i.e.
Suspensions
- Remove the fixing pin to the engine and collect the spacer. - Now the swinging arm is free.
- Remove the swinging arm from the vehicle; first release it from the engine side and then from the chassis side.
Overhaul
- Check that the silent-blocks are in good conditions. - Otherwise, replace the swinging arm.
SUSP - 251
Suspensions
Vespa LXV 125 i.e.
Refitting
- To fit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torques.

Part A 33 to 41 Part B 44 to 52 Part C 33 to 41
Shock absorbers Removal

- Adequately support the rear part of the vehicle. - Remove the battery. - Undo the indicated upper fixing screw to the chassis.
- Unscrew the lower fixing pin to the transmission crankcase.
SUSP - 252
Vespa LXV 125 i.e.
Suspensions
Refitting
- To fit, follow the removal steps but in reverse order; be careful to tighten to the prescribed torques.

Shock absorber/engine pin torque 33 to 41 Nm Shock absorber/chassis nut torque 20 - 25 Nm
Centre-stand
REMOVAL - Use a jack to support the vehicle properly. - Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the pin from the right side. - Remove the centre stand. FITTING - On refitting tighten the nut to the specified torque.

Centre stand screw 32 to 40
SUSP - 253
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Vespa LXV 125 i.e.
Braking system
Front brake calliper Removal

- Remove the front wheel. - Remove the two screws fixing the brake calliper to the mounting bracket, then remove the brake calliper with the pipe from the disc. - Remove the brake pad retention pin snap ring. - Remove the brake pad retention pin using a plug. - Complete the extraction of the protection cover, the springs and the pads.
N.B. IF BRAKE CALLIPER REPLACEMENT IS NEEDED, BEFORE REMOVING THE CALLIPER CLAMPS TO THE MOUNTING BRACKET, LOOSEN THE OIL JOINT FITTING.
Refitting
- Insert the brake pads in the calliper. - Insert the pad fixing pin and the retention screw being careful to position the terminals of it pointing towards the bleed screw as shown in the photo. - Insert the clip on the pad fixing pin
N.B. FAILURE TO RESPECT THE PAD POSITIONING REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COULD COMPROMISE PROPER BRAKE FUNCTIONING AND NOISELESSNESS.
BRAK SYS - 255
Braking system
Vespa LXV 125 i.e.
- Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the mounting bracket with the two screws with spring washer to the prescribed torque
- If it is disconnected, fasten the brake pipe joint to the calliper and tighten to the prescribed torque - Purge the circuit and refit the front wheel

Brake calliper mounting clamping 20 to 25 Nm Brake pipe connection 20 to 25 Nm
Front brake disc
BRAK SYS - 256
Vespa LXV 125 i.e.
Braking system
Removal
- Remove the front wheel - Remove the front brake calliper - Remove the hub and the disc operating on the wheel axle nut - Adequately support the hub with the disc and operating on the five screws shown in the photograph, remove the brake disc
Refitting
- Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the 5 screws to the specified torque

Brake disc screws: 6 +0.5 -1 Nm
BRAK SYS - 257
Braking system
Vespa LXV 125 i.e.
Disc Inspection
- Remove the front wheel - Use a micrometer to check the disc thickness as shown in the photograph - Repeat the measurement in at least 6 points on the disk - Remove the front brake calliper - In order to secure the appropriate tool adequately use a metal plate with M8 threaded hole and fix it to one of the two front brake calliper attachment points - Place the dial gauge on the disk outer edge - Make the wheel hub turn and check the disk deviation
Specific tooling
020335Y Magnetic mounting for dial gauge
Characteristic
Standard thickness: 4 +0.2-0.2 mm Max. deviation allowed: 0.1 mm
Front brake pads Removal

- Remove the front wheel - Remove the brake calliper - Remove protection cover, the pin and the spring - Remove the brake pads - Check that there are no faults or warping. If there are, replace them. - Check that the thickness of the friction material is more than 1.5 mm. Otherwise, replace it. - The replacement must be made with greater residual thickness if the brake pad has not worn
BRAK SYS - 258
Vespa LXV 125 i.e.
Braking system
evenly. A 0.5 mm thickness difference in the residual friction material is permitted
Refitting
- Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the lock on the bolt and then the protection cover - Fix the brake calliper to the bracket and tighten the two screws to the specified torque.
CAUTION BEFORE USING THE BRAKE, OPERATE THE LEVER A FEW TIMES.

Rear brake calliper tightening screw 20 to 25 Nm
Fill
BRAK SYS - 259
Braking system
Vespa LXV 125 i.e.
Front
- Remove the rubber cap from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. - With the right-hand brake lever, load the system and bring it up to the required pressure. - Keeping the right-hand brake lever pulled, loosen the bleed screw to purge the air. Then tighten the bleed screw - Release the brake lever - Repeat the operation until only brake fluid comes out of the rubber pipe. - Remove the fluid recovery pipe and refit the rubber cap over the bleed screw. - Top up the brake fluid to the right level in the reservoir. If necessary, bleeding can be done using a special vacuum pump
N.B.
DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y Mity-Vac vacuum-operated pump

System bleed calliper fitting: 20 to 25 Nm
Brake fluid level check

- Rest the vehicle on its centre stand on flat ground. - The brake fluid reservoir has a sight glass A made of transparent material; the quantity of liquid contained in the sight glass indicates the level of fluid in the reservoir. - When the sight glass A is full, the level inside the reservoir is above the MIN level; when it is partially full, the level has dropped to the MIN level;
BRAK SYS - 260
Vespa LXV 125 i.e.
Braking system
when it is fully empty, the level of fluid in the reservoir is below the MIN level.
N.B. THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF REQUIRED. TOP UP THE PUMP RESERVOIR, IF REQUIRED, CONSIDERING THAT THE "MAX." LEVEL MUST ONLY BE OBTAINED WITH NEW PADS.
- Under standard climatic conditions, replace fluid as indicated in the scheduled maintenance table.
Front brake pump Removal

- Remove the two screws fixing the brake pump to the handlebar indicated in the photograph - Remove the oil pipe joint from the pump - Remove the connector from the stop lights switch
Refitting
For the refit, carry out the operations in the reverse order from which they were removed, observing the tightening torques and installing the collar with the word "UP" upwards.

Oil pipe joint to the pump: 20 - 25 Brake pump fixing screws to the handlebar: 7 to 10 Nm
BRAK SYS - 261
Braking system
Vespa LXV 125 i.e.
Rear drum brake

Once the silencer and the wheel have been removed, follow these steps: 1.Remove the shoe springs 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 springs using the specific pliers.
Specific tooling
020325Y Pliers for brake-shoe springs
BRAK SYS - 262
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Vespa LXV 125 i.e.
Seat
Remove the saddle opening cable Remove the four screws shown in the figure and the rear seat from the chassis saddle.
Unscrew the two screws of saddle fixing hook cover.
To remove the cable and the sheath: - Remove the elastic ring and unscrew the cable end from the seat on the saddle fixing hook. - Remove the other end of the cable from the fixing seat on the locking block.
CHAS - 264
Vespa LXV 125 i.e.
Chassis
Instrument panel
- Remove the front central cover - Remove the shield back plate - Remove the two fixing screws of the instrument panel.
- Remove the odometer cable. - Remove the connector of the electric connections from the instrument panel
Instrument panel lower shell - Remove the instrument panel - Remove the handlebar - Remove the two screws indicated in the figure.
- Remove the screw indicated in the figure, placed under the handlebar light fitting
CHAS - 265
Chassis
Vespa LXV 125 i.e.
Headlight assy.
- Remove the four fixing screws from the light support.
- Collect the nut in correspondence with the rear screws.
- Undo the two screws fixing of the front frame.
- Disconnect the frame with headlight and the connections of the bulbs. - Remove the chassis from the headlight body.
CHAS - 266
Vespa LXV 125 i.e.
Chassis
Knee-guard
- Unscrew the two screws shown in the figure placed under the front central cover.
- Remove the 3 screws shown in the figure, placed inside the glove-box; they can be reached opening the glove-box door. - Remove the shield back plate by pulling it upwards.
Taillight assy.
- Undo the two fixing screws and remove the rear light unit.
- Undo the screw indicated and disconnect the connector.
CHAS - 267
Chassis
Vespa LXV 125 i.e.
Footrest
- Remove the leg shield back plate. - Remove the side fairings. - Remove the central tunnel inspection door. From both sides, unscrew: - The fixing screw at the back.
- The fixing screw on the central part.
- The fixing screw at the front.
- Remove the footrest.
CHAS - 268
Vespa LXV 125 i.e.
Chassis
Side fairings
- Undo the upper screw and the smallest lower screw.
- Detach the seats on the fairing.
License plate holder

- Remove the side fairings. - Working on both sides, undo the two screws indicated.
- Remove the license plate light.
CHAS - 269
Chassis
Vespa LXV 125 i.e.
Air filter
- Remove the helmet compartment. - Remove the side fairings. - Undo the two indicated clamps to the crankcase.
- Undo the two clamps indicated.
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
CHAS - 270
Vespa LXV 125 i.e.
Chassis
Front central cover

- Remove the "PIAGGIO" clip-on badge - Unscrew the screw indicated in the figure - Remove the grille
CHAS - 271
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Vespa LXV 125 i.e.
Pre-delivery
Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt
Tightening torques inspection

Lock check - Safety fasteners - Fixing screws Safety fasteners: Rear shock absorber upper retainer Rear shock absorber lower clamping Front wheel axle nut Front wheel screws Wheel hub nut Front brake calliper fixing screws Swinging arm - chassis pin Engine-swinging arm pin Engine arm pin - Chassis arm Handlebar lock nut Lower steering ring nut Upper steering ring nut
Electrical system
Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel gauge - Instrument panel warning lights PRE DE - 273
Pre-delivery
Vespa LXV 125 i.e.
- Horn
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 THE LIFE OF THE BATTERY.
WARNING
KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING. REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
Level check: - Hydraulic braking system fluid level. - Rear hub oil level - Engine oil level
Road test
Test ride - Cold start - Instrument operations - Response to the throttle control - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise
PRE DE - 274
Vespa LXV 125 i.e.
Pre-delivery
Static test
Static control after the test ride: - Restarting when warmed up - 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 Checks: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Proper general functioning and no abnormal noise check Others - Check documentation - Check the chassis and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories
PRE DE - 275
A
Air filter: 36, 270
B
Battery: 46, 64, 82, 93 Brake: 255, 256, 258, 260262 Brake fluid: 260
C
Checks: 73
E
Engine oil: 37
F
Fuel: 187, 203 Fuses: 92
H
Headlight: 42, 266 Horn: 86 Hub oil: 35
I
Identification: 8 Instrument panel: 265
M
Maintenance: 7, 33
O
Oil filter: 39
R
Recommended products:
S
Shock absorbers: 252 Spark plug: 33 Suspension: 46
T
Transmission: 9, 45, 120, 131, 141 Turn indicators: 70 Tyres: 13
V
Vehicle: 8, 115, 116

Vespa LXV 125 I.E. (EN)

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Vespa LXV 125 I.E. (EN)

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SERVICE STATION MANUAL

665333 IT-665334 EN-665335 FR-665336 DE-665337 ES-665339 PT-665340 NL

Vespa LXV 125 i.e.

SERVICE STATION MANUAL

Vespa LXV 125 i.e.

SERVICE STATION MANUAL

Vespa LXV 125 i.e.

Vespa LXV 125 i.e.

Dimensions and mass

WEIGHTS AND DIMENSIONS

Vespa LXV 125 i.e.

Final reduction gear

Vespa LXV 125 i.e.

Vespa LXV 125 i.e.

ENGINE STOP SWITCH

Vespa LXV 125 i.e.

Vespa LXV 125 i.e.

Frame and suspensions

Wheels and tyres

Vespa LXV 125 i.e.

HEAD AND CYLINDER

Vespa LXV 125 i.e.

CRANKCASE AND CRANKSHAFT

Vespa LXV 125 i.e.

Overhaul data Assembly clearances Cylinder - piston assy.

PISTON TO CAST IRON CYLINDER COUPLING

Vespa LXV 125 i.e.

Dimensions 57.4x1 57.4x1 57.4x2.5 57.6x1 57.6x1 57.6x2.5

Maximum clearance after use: 1 mm

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

Crankshaft/crankcase axial clearance: 0.15 to 0.40

Vespa LXV 125 i.e.

Slot packing system

Vespa LXV 125 i.e.

Vespa LXV 125 i.e.

Bell for OD 42-mm bearings

Calliper to extract 15-mm bearings

Calliper to extract 15-mm bearings

Bell for bearings, OD 39 mm

Calliper for circlips

Vespa LXV 125 i.e.

Stores code 005095Y

Description Engine support

Punch for fitting steering bearing seat on steering tube

Punch for removing steering bearings from headstock

Front suspension service tool

Vespa LXV 125 i.e.

Stores code 020036Y

Wrench for steering tube ring nut

Support base for checking crankshaft alignment

Air heater mounting

Vespa LXV 125 i.e.

Stores code 020193Y

Description Oil pressure check gauge

Crankcase splitting plate

Driven pulley assembly sheath

Clamp to fit piston on cylinder

Punch for assembling valve seal rings