VESPA LXV 125 Mode d’emploi

Service station manual

633852 IT - 633853 EN - 633854 FR - 633855 DE -

633856 ES - 633857 PT - 633858 NL - 633859 EL

LXV 125

Service station

manual

LXV 125

The descriptions and illustrations given in this publication are not binding. While the basic specifications

as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

Service station manual

LXV 125

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It

is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical

principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair

operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary

equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to special tools, along

with the special tool catalogue.

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

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

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

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

injury.

Safeguarding the environment Sectionsmarked with this symbol indicatethe correct use of thevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

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.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling

members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.

Characteristics LXV 125

CHAR - 6

Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Engine prefix ZAP M444M

Chassis prefix ZAP M443010000÷0000

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Kerb weight 114 ± 5 kg

Overall height 1180 mm

Width 740 mm

Wheelbase 1280 mm

Length 1800 mm

LXV 125 Characteristics

CHAR - 7

Engine

ENGINE

Specification Desc./Quantity

Engine Single-cylinder, 4-stroke Piaggio LEADER

Timing system Single overhead camshaft (SOHC) with 2 valves

Valve clearance intake 0.10

outlet 0.15

Bore x stroke 57.0 x 48.6 mm

Cubic capacity 124 cc

Carburettor KEIHIN CVK26

Engine idle speed 1650 ± 100 rpm

Start-up Electric

Max power to the shaft 10.5 CV at 8250 rpm

Cooling Forced air circulation.

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with torque server,

V belt, automatic clutch, gear reduction unit and transmission

housing with forced air circulation cooling.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 61 in³ (1,000 cm³)

Rear hub oil ~ 100 cm³

Fuel tank capacity ~ 8.5 litres (2 l of which is reserve)

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Start-up Electric

Spark plug Champion RG6YC- NGK CR7EB

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Chassis Unitised body made of stamped plate.

Steering and suspensions Steering tube articulated on the front wheel carrier hub; heli-

coidal spring suspension and double-acting hydraulic shock

absorber; rear with double-acting shock absorber and coaxial

spring adjustable to 4 positions at preloading.

Characteristics LXV 125

CHAR - 8

Brakes

BRAKES

Specification Desc./Quantity

Front brake Disc brake (Ø 200 mm) with hydraulic control (lever on the far

right of the handlebar) and fixed calliper.

Rear brake Ø110 mm drum brake

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Front wheel rim Die-cast aluminium alloy; 2.50 x11"

Front tyre Tubeless; 110/70-11"

Rear wheel rim Die-cast aluminium alloy; 3.00 x 10"

Rear tyre Tubeless; 120/70-10"

Front tyre pressure 1.6 bar

Rear tyre pressure 2 bar

Rear wheel pressure (rider and passenger): 2.3 bar

Carburettor

CARBURETTOR SETTING

Specification Desc./Quantity

Type CVEK26

Body stamping CVK

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Maximum jet 82

Maximum air jet (on the body) 85

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 2

Starter jet 42

Starter air jet (on the body) Ø 1.5

Starter pin travel 10 mm (at 24°)

Starter resistance 20 Ohm (at 24°)

Kehin

CARBURETTOR SETTING

Specification Desc./Quantity

Type CVEK26

Body stamping CVK

Throttle valve diameter Ø 26.5

Diffuser diameter Ø 26.4

Maximum jet 82

Maximum air jet (on the body) 85

Tapered pin stamping NELA

Throttle valve spring 130 ÷ 180 gr.

Minimum jet 35

Idle air jet (on the body) 150

Idle mixture adjustment screw initial opening 2

Starter jet 42

Starter air jet (on the body) Ø 1.5

LXV 125 Characteristics

CHAR - 9

Specification Desc./Quantity

Starter pin travel 10 mm (at 24°)

Starter resistance 20 Ohm (at 24°)

Tightening Torques

LUBRICATION

Name Torque in Nm

Hub oil drainage cap 15 ÷ 17

Oil filter 4 ÷ 6

Oil pump cover screws 5 - 6

Oil pump screws 5 - 6

Pump control pulley screw 10 ÷ 14

Chain cover screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

Blow-by recovery duct fixing screws 3 - 4

HEAD AND CYLINDER

Name Torque in Nm

Ignition spark plug 12 ÷ 14

Head cover screws 11 ÷ 13

Nuts fixing head to cylinder (*) 28 ÷ 30

Head fixing screws (external) 11 ÷ 13

Starter ground screw 7 ÷ 8.5

Flywheel cover screw 1 ÷ 2

Flywheel air manifold screw 3 ÷ 4

Pressure reducer counterweight retainer 7 ÷ 8.5

Camshaft pulley screw 12 ÷ 14

Timing chain tensioner slider screw 10 ÷ 14

Starter ground support screw 11 ÷ 15

Tensioner screws 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Camshaft retention plate screw 5 - 6

Nut fixing muffler to cylinder head 16 ÷ 18

Head intake manifold screw 11 ÷ 13

TRANSMISSION

Name Torque in Nm

Drive pulley nut 75 ÷ 83

Transmission cover screw 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screw 24 ÷ 27

Clutch unit nut on driven pulley 45 ÷ 50

FLYWHEEL

Name Torque in Nm

Flywheel fan screws 3 ÷ 4

Stator assembly screws (°) 3 ÷ 4

Flywheel nut 52 ÷ 58

Pick-up screw 3 ÷ 4

(°) Apply LOCTITE 243 threadlock

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmission-side half

shaft) screws 4 ÷ 6

Oil filter on crankcase fitting 27 ÷ 33

Rear brake cam tightening screw 11 ÷ 13

Engine-crankcase coupling screws 11 ÷ 13

Pre-filter cap 24 ÷ 30

Characteristics LXV 125

CHAR - 10

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