Replacing Fuel Lines On A Vespa Lx50: Step-By-Step Guide

Changing the fuel lines on a 2007 Vespa LX50 is a simple task that can be completed by following a few easy steps. The fuel line runs under the gas tank, through the frame, and up to the carb airbox. Before beginning the process, it is important to gather all the necessary parts, including a fuel line of the exact right size to ensure it reaches the carb without any kinks. The first step is to remove the seat and the rear tank bolts. Next, access the carburetor by removing the carb airbox top and air filter. The fuel banjo bolt and carb air bellows can then be taken off, followed by the removal of the fuel hose clamp and banjo. With the fuel lever turned to the middle position, the fuel lever frame grommet can be taken out. The fuel tank can now be pulled up and removed, and with the help of a friend or a towel, the old clamp and line can be replaced with a new line and clamp. The new fuel line is then fed through the frame to the carb, and a rubber frame grommet can be installed if needed. The tank is then put back into place, and the remaining components, such as the air filter and carb box top, are reinstalled.

Removing the seat and rear tank bolts

To remove the seat and rear tank bolts of a Vespa LX50, start by removing the three seat bolts. You will need to get all your parts together before you begin. You can refer to the Vespa LX50 Workshop Manual for a list of parts. Once you have the necessary parts, remove the three bolts holding the seat in place. After the seat is removed, you can access and remove the two rear tank bolts.

It is important to note that the fuel line must be the exact right size. If it is too short, it will not reach the carb, and if it is too long, it will kink and prevent the fuel from gravity-feeding to the carb. Therefore, ensure you purchase the correct fuel line from a reputable scooter dealer and have them double-check the length.

With the seat and rear tank bolts removed, you can proceed to the next step of removing the carb airbox top and air filter to access the carburetor. This will allow you to detach the fuel banjo and remove the carb air bellows if necessary.

Additionally, having a helper to hold the fuel tank while you work on the tap can be beneficial. If you don't have an extra pair of hands, use a towel to protect the frame from getting scraped by the tank.

Accessing the carburettor

To access the carburettor, first remove the seat by taking out the three bolts holding it in place. Then, remove the two rear bolts from the fuel tank. Next, remove the carb airbox top and the air filter to expose the carburettor. Now, you can remove the bolt holding the fuel banjo to the carburettor and take off the carb air bellows. If the bellows are in poor condition, you may want to replace them.

With the banjo bolt loosened, pull it up and away from the carburettor for better access. You can now remove the fuel hose clamp and the banjo itself. If your fuel line is old, you may need to cut it with a razor to get the banjo off.

Now, turn the fuel lever to the middle position and remove the fuel lever frame grommet. This will allow you to pull the fuel tank up and out of the scooter. You may need assistance to hold the tank while you work. Once the tank is out, you will have access to the carburettor and can begin fuel line replacement.

Removing the fuel lever frame grommet

To remove the fuel lever frame grommet, you will first need to turn the fuel lever to the middle position. This will allow you to move the lever through the frame. Once the lever is in the middle position, you can then remove the grommet.

It is important to ensure that you have the correct size fuel line for your Vespa. If the fuel line is too short, it will not reach the carb, and if it is too long, it will kink and prevent the fuel from gravity feeding to the carb. It is recommended to buy the correct fuel line from a reputable scooter dealer and have them double-check the length.

When replacing the fuel line, you will also need to remove the seat and the two rear tank bolts. This will give you access to the carb airbox, which you will need to remove the top of, along with the air filter, to access the carburetor. On the carb, remove the bolt holding the fuel banjo, and then remove the carb air bellows if it is in bad shape.

With the banjo loose, pull it up and away from the carb for easy access. Remove the fuel hose clamp and then the banjo itself. If your fuel line is old, you may need to cut it with a razor to remove the banjo.

After removing the banjo, you can then remove the fuel tank. Pull up on the back of the tank and manhandle it slightly to get it out. Once the tank is out, you will have access to the fuel tap. If you are just replacing the fuel line, you only need to pull the tank up enough to access the fuel tap.

Removing the fuel tank

Before you begin, make sure you have all the parts you need. The fuel line must be the exact right size. Too short, and it won't reach the carb; too long, and it will kink and prevent the fuel from gravity-feeding to the carb. It is recommended to buy the correct fuel line from a reputable scooter dealer.

First, remove the seat by taking out the three seat bolts. Then, take out the two rear tank bolts. Next, remove the carb airbox top and the air filter to access the carburetor. On the carb, remove the bolt that holds the fuel banjo, then the carb air bellows. If it is worn, now is a good time to replace it.

With the banjo loose, pull it up and away from the carb. Remove the fuel hose clamp and then the banjo itself. If your fuel line is old, you may need to cut it with a razor to get the banjo off. Next, remove the fuel lever frame grommet. Turn the fuel lever to the middle position to get it through the frame.

Now, you can remove the fuel tank. Pull up on the back of the tank. Rally tanks are larger than most, so you will need to manoeuvre it to get it out. If you are only replacing the fuel line, pull the tank up just enough to access the fuel tap. If you are also replacing the oil, pull the tank further up to access the bottom of the oil tank.

At this point, it is helpful to have a friend hold the tank while you work on the tap. If you don't have an extra pair of hands, use a towel to protect the frame from getting scraped by the tank. Once you have access to the tap, simply remove the old clamp and line. Then, put the clamp on your new line and attach it to the end of the fuel tap. Heating the fuel line with a heat gun will make it more pliable and easier to slip onto the end of the tap.

With the line attached at the top to the fuel tap, feed it through the frame to the carb. Keep the tank out of the scooter and loop the fuel line under the fuel control rod, then up through the frame hole. If your scooter does not have a rubber frame grommet for the fuel line, now is the time to install one.

Then, with the tank still out of the scooter, attach a string or something similar to the end of the fuel rod. Feed the free end of the string through the hole in the frame for the fuel rod. This will help guide the rod to the hole while you put the tank back into the frame. Then, gently put the tank back into place. Once the tank is back in the frame, reinstall the frame grommets for the fuel control rod and the oil tank sight glass.

Attaching the new fuel line

To attach the new fuel line, you will need to first ensure you have purchased the correct length of fuel line from a reputable scooter dealer. It should be long enough to reach the carb without any kinks. Once you have the correct fuel line, follow these steps:

Remove the fuel tank by pulling up on the back of it. You may need a friend to help hold the tank while you work on the fuel tap. If you are unable to remove the fuel tank, you can simply pull it up enough to access the fuel tap.

Remove the old clamp and fuel line from the fuel tap. This is located at the bottom of the fuel tank. Take your new fuel line and attach the clamp to it, then attach the fuel line to the end of the fuel tap. You may need to use a heat gun to heat up the fuel line and make it pliable, as this will make it easier to attach.

Now, feed the fuel line through the frame to the carb. Keep the tank out of the scooter and loop the fuel line under the fuel control rod, then up through the frame hole. If your scooter does not have a rubber frame grommet for the fuel line, you should install one now.

Next, attach a string or something similar (such as a long twist tie) to the end of the fuel rod. Feed the free end of the string through the hole in the frame for the fuel rod. This will help guide the rod back into the hole when you replace the fuel tank.

Once the string is in place, gently put the fuel tank back into the frame. Reinstall the frame grommets for the fuel control rod and the oil tank sight glass.

Now, on the carb end of the fuel line, feed it through the hole in the bottom of the airbox. If the grommet for the fuel line is missing, be sure to replace it now. Pull the fuel line so that you have some extra slack inside the airbox.

Finally, heat the end of the fuel line with a heat gun and install the hose clamp, followed by the carb banjo. Reinstall the banjo to the carb and button everything up by reinstalling the seat and fuel tank bolts. Ensure the seat is in the correct position before tightening the bolts.

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