VESPA LXV 50 Mode d’emploi

SERVICE STATION MANUAL

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

633864 ES - 633865 PT - 633866 NL - 633867 EL

Vespa LXV 50

SERVICE STATION

MANUAL

Vespa LXV 50

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

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

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

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

required for manufacturing or construction reasons.

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

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

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

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

SERVICE STATION MANUAL

Vespa LXV 50

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

Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a

basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important

changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this

manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are

unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along

with the specific tool catalogue.

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

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

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

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

injury.

Safeguarding the environment 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.

Vespa LXV 50 Characteristics

CHAR - 7

Vehicle identification

VEHICLE IDENTIFICATION

Specification Desc./Quantity

Engine prefix C381M ÷ 1001

Chassis prefix ZAPC38102 ÷ 1001

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Kerb weight 98 ± 5 kg

Overall height 1180 mm

Wheelbase 1280 mm

Length 1800 mm

Width 740 mm

Characteristics Vespa LXV 50

CHAR - 8

Engine

ENGINE

Specification Desc./Quantity

Engine type Two-stroke, single cylinder Piaggio Hi-PER2

Bore x stroke 40 X 39.3 mm

Cubic capacity 49.40 cc

Compression ratio 9.9 ±0.5 : 1

Carburettor DELL'ORTO PHVA 17.5

Air filter Sponge impregnated with fuel mixture (50% SELENIA air filter

oil and 50% unleaded petrol).

Engine idle speed ~ 1800 ± 100 rpm

Starting system electric starter/kickstarter

Lubrication With blend and variable oil variable according to the engine

revolutions and the throttle valve opening by means of a pump

controlled by the driving shaft with toothed belt.

Fuel supply Gravity feed, with unleaded petrol (with a minimum octane rat-

ing of 95) with carburettor.

Cooling Forced air circulation.

Transmission

TRANSMISSION

Specification Desc./Quantity

Transmission With automatic expandable pulley variator, torque server, V

belt, automatic clutch, gear reduction unit.

Capacities

CAPACITY

Specification Desc./Quantity

Rear hub oil Quantity: approx. 85 cc

oil mixer tank Plastic, capacity ~ 1.2 l

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

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Type of ignition Capacitive discharge type electronic ignition, with incorporated

high voltage coil

Ignition advance (before TDC) Fixed 17° ± 1

Recommended spark plug CHAMPION RN2C

Battery 12V-4Ah

Main fuse 7.5 A

Generator In alternate current with three output sections

Frame and suspensions

FRAME AND SUSPENSIONS

Specification Desc./Quantity

Type Unitised body made of stamped plate

Vespa LXV 50 Characteristics

CHAR - 9

Specification Desc./Quantity

Front suspension Single arm suspension with swinging arm articulated to the

steering tube. Hydraulic double-acting shock absorber and co-

axial spring

Front suspension stroke 70 mm

Trail (suspension rebounded/compressed) 71/68 mm

Rear suspension Single hydraulic double-acting shock absorber, helicoidal co-

axial spring. Chassis engine support with swinging arm.

Rear suspension travel: 83.5 mm

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 tyre size 110/70"-11"

Rear tyre size 120/70-10"

Front tyre pressure 1.6 bar

Rear tyre pressure: 2 bar

Light alloy rims (Front rim) 2.50" x 11"

Light alloy rims (rear rim) 3.00 x 10"

N.B.

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

PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

Secondary air

Follow these steps to clean the sponge filters of

the secondary air system:

1) Remove the snap-on plastic cover (1) on the

transmission cover using a small screwdriver as a

leveronthe retainingtonguesinordertoinsertone

of the three slots found on that cap.

2) Wash the polyurethane sponge with water and

soap, dry all components with compressed air and

refit to place. Refit the intake cap respecting the

angle reference.

3)Undothe two fixing screws (2) on the aluminium

cover of the secondary air housing in order to

reach the polyurethane sponge inside that hous-

ing; clean as indicated in point 2) and refit all

Characteristics Vespa LXV 50

CHAR - 10

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