Professional Documents
Culture Documents
The descriptions and illustrations given in this publication are not binding. While the basic features 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 accessory supplies, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions shown in this publication are available in all Countries. The availability of individual versions should be confirmed with the official Piaggio sales network. " Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - After-Sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
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 SUSPENSIONS BRAKING SYSTEM COOLING SYSTEM CHASSIS PRE-DELIVERY TIME
CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG SUSP BRAK SYS COOL SYS CHAS PRE DE TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
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 wellventilated, 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 open 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 solvent. Lubricate all the work surfaces except the tapered couplings before refitting. - 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 measurement. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 2
Characteristics
Vehicle identification
Chassis prefix: M36601 Engine prefix: M368M
CHAR - 3
Characteristics
Engine
ENGINE
Specification Type Cubic capacity Bore x stroke Compression ratio Engine idle speed Timing system Valve clearance Max. power MAX. torque Lubrication Desc./Quantity Single-cylinder, 4-stroke 124 cm 57 x 48.6 mm 12 0.5: 1 1650 100 rpm 4 valves, single overhead camshaft, chain-driven. Inlet: 0.10 mm Outlet: 0.15 mm 11 kW at 10,000 rpm 12 Nm at 8,000 rpm Engine lubrication with lobe pump (inside crankcase) controlled by a chain with double filter: mesh and paper. 4 bar 0.8 bar KEIHIN CVEK 30 carburettor and electrical fuel pump. Forced coolant circulation system. Unleaded petrol (95 RON) absorption-type exhaust muffler with catalytic converter. EURO 3
Lubrication pressure Minimum lubrication pressure (100 C) Fuel supply Cooling Fuel Exhaust muffler Emission regulations
Transmission
TRANSMISSION
Specification Main drive Desc./Quantity Automatic expandable pulley variator with torque server, V-belt, automatic self-ventilating centrifugal dry clutch Gear reduction unit in oil bath.
Final reduction
CHAR - 4
Characteristics
Capacities
CAPACITY
Specification Engine oil Transmission oil Cooling system fluid Fuel tank (reserve) Desc./Quantity 1.1 l 150 cm ~2l ~ 12 l (~ 2.5 l)
Electrical system
ELECTRICAL SYSTEM
Specification Start-up Ignition Ignition advance Spark plug Alternative spark plug Battery Generator Desc./Quantity Electric Capacitive discharge ignition, with variable advance and separate HV coil. 10 1 at 2,000 rpm CHAMPION RG4HC NGK CR8EB 12V-12Ah In alternating current
Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity 260-mm disc brake with hydraulic control activated by the handlebar right-side lever. 240 mm disc brake with hydraulic control activated by the handlebar left-side lever.
Characteristics
Specification Front rim Rear rim Front tyre Rear tyre Front tyre pressure (with passenger) Rear tyre pressure (with passenger)
Desc./Quantity 14'' x 3.50 12'' x 3.00 Tubeless 120/70 - 14'' 55P Tubeless 130/70 12'' 62P 2.3 bar (-) 2.6 bar (-)
Tightening Torques
REAR BRAKE
Name Rear brake disc screws() Rear brake calliper-pipe fitting Rigid / flexible pipe fitting Rear brake pump-pipe fitting Rear brake calliper fixing screws Torque in Nm 5 6.5 20 25 13 18 16 20 20 25
REAR BRAKE
Product () Loctite 243 Description Medium strength threadlock Specifications Apply LOCTITE 243 mediumstrength threadlock
CHAR - 6
Characteristics
FRONT BRAKE
Name Oil bleed screw Disc tightening screw () Brake fluid pipe-calliper fitting Brake fluid pump - hose fitting Tightening screw for calliper support to the fork Screw tightening calliper to the support Torque in Nm 812 5 6.5 20 25 16 20 20 25 42 52
REAR SUSPENSION
Name Upper shock absorber clamp Shock absorber lower clamp Shock absorber-crankcase attachment bracket Rear wheel axle Muffler arm clamping screws Torque in Nm 33 41 33 41 20 25 104 126 27 30
FRONT SUSPENSION
Name Fork leg screw Front wheel shaft Fork plate screw Torque in Nm 67 45 50 25 34
CHASSIS
Name Centre stand bolt Side stand bolt () Engine arm bolt - frame arm Swinging arm buffer nut Frame-swinging arm bolt Engine-swinging arm bolt Torque in Nm 25 30 35 40 33 41 64 - 72 64 - 72 64 - 72
CHASSIS
Product () Loctite 243 Description Medium strength threadlock Specifications Apply LOCTITE 243 mediumstrength threadlock
STEERING
Name Upper steering ring nut Steering lower ring nut Handlebar fixing screw Fixing screws for handlebar control assembly Ubolts Torque in Nm 30 33 10 13 then loosen by 90 50 55 7 10
ENGINE - COOLING
Product () Loctite 243 Description Medium strength threadlock Specifications Apply LOCTITE 243 mediumstrength threadlock
CHAR - 7
Characteristics
ENGINE - FLYWHEEL
Name Pick-Up clamping screws Stator assembly screws () Flywheel cover fixing screws Flywheel nut (250) Screw fixing freewheel to flywheel Torque in Nm 34 34 5-6 94 102 13 15
ENGINE - TRANSMISSION
Name Rear hub cover screws Driven pulley shaft nut Transmission cover screws Drive pulley nut Clutch unit nut on driven pulley Belt support roller screw Torque in Nm 24 27 54 60 11 13 75 83 55 60 11 13
LUBRICATION
Name Hub oil drainage plug Oil filter on crankcase fitting Engine oil drainage plug/mesh filter Oil filter Oil pump cover screws Screws fixing oil pump to the crankcase Oil pump control crown screw Oil pump cover plate screws Torque in Nm 15 17 27 33 24 30 46 0.7 0.9 5-6 10 14 46
CHAR - 8
Characteristics
Torque in Nm 10 14 12 14
CHAR - 9
Characteristics
Name Piston 2nd Oversize Piston 2nd Oversize Cylinder 3rd Oversize Cylinder 3rd Oversize Piston 3rd Oversize Piston 3rd Oversize
Initials C2 D2 A3 B3 C3 D3
Cylinder 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 57.359 57.366 57.366 57.373 57.545 57.552 57.552 57.559 57.559 57.566 57.566 57.573
Play on fitting 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059
C-C
C-C
B-B
CRANKSHAFT - CRANKCASE
Name Crankshaft Crankshaft Crankcase Crankcase Description Dimensions Initials Category 1 Class 2 Category 1 Class 2 Quantity 28.998 29.004 29.004 29.010 32.959 32.965 32.953 32.959
CHAR - 10
Characteristics
Fitting clearances Crankshaft/crankcase axial clearance (H): 0.15 0.40 mm (when cold)
CHAR - 11
Characteristics
Measurement A to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE.
CHAR - 12
Characteristics
Characteristic
Compression ratio 12 0.5: 1
Measurement A to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.
N.B.
NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYLINDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD CENTRE POSITION AND ON A RECTIFIED PLANE.
CHAR - 13
Characteristics
Oversizes
OVERSIZES
Name Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st Oversize Oil scraper ring 1st Oversize 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 x 1 57 x 1 57 x 2.5 57.2 x 1 57.2 x 1 57.2 x 2.5 57.4 x 1 57.4 x 1 57.4 x 2.5 57.6 x 1 57.6 x 1 57.6 x 2.5 Initials A A A A A A A A A A A A 0.15 0.35 Quantity 0.15 0.30 0.10 0.30 0.15 0.35 0.15 0.30 0.10 0.30 0.15 0.35 0.15 0.30 0.10 0.30 0.15 0.35 0.15 0.30
CHAR - 14
Characteristics
Products
RECOMMENDED PRODUCTS TABLE
Product AGIP ROTRA 80W-90 Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil to lubricate flexible transmisOil for 4-stroke engines sions (throttle control) Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Grease for brake levers, throttle White calcium complex soapbased spray grease with NLGI 2; ISO-L-XBCIB2 Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil Brake fluid FMVSS DOT 4 Synthetic fluid coolant Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 Description Rear hub oil
CHAR - 15
Characteristics
CHAR - 16
INDEX OF TOPICS
TOOLING
TOOL
Tooling
APPROPRIATE TOOLS
Stores code 020151Y Description Air heater
020331Y
Digital multimeter
020333Y
020334Y
001467Y014
TOOL - 2
Tooling
Description 15 mm guide
020335Y
020565Y
020439Y
17 mm guide
020359Y
42x47-mm adaptor
TOOL - 3
Tooling
Description 20 mm guide
020459Y
020458Y
005095Y
Engine support
008564Y
Flywheel extractor
020434Y
TOOL - 4
Tooling
020424Y
020431Y
020193Y
020306Y
020360Y
Adaptor 52 x 55 mm
TOOL - 5
Tooling
020375Y
Adaptor 28 x 30 mm
020376Y
Adaptor handle
020444Y
020330Y
001467Y035
TOOL - 6
Tooling
020319Y
020287Y
020263Y
020262Y
020430Y
TOOL - 7
Tooling
020426Y
020425Y
020423Y
020414Y
28-mm guide
020393Y
TOOL - 8
Tooling
020455Y
10-mm guide
020442Y
020440Y
020329Y
020357Y
32 x 35 mm adaptor
TOOL - 9
Tooling
020456Y
24 mm adaptor
020332Y
020074Y
020055Y
TOOL - 10
Tooling
001330Y
020454Y
020622Y
020444Y011
adapter ring
020444Y009
46x55 Wrench
001467Y
TOOL - 11
Tooling
020444Y010
adapter ring
TOOL - 12
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequentially. The icon selected remains ON and the other is no longer displayed. 3. Press the "CLOCK" button again for more than 3 seconds to reset the relative maintenance step and the icon is no longer displayed.
Maintenance chart
EVERY 2 YEARS
Action Coolant - change Brake fluid - change secondary air filter (outside) - cleaning
EVERY 3,000 KM
10' Action Engine oil - level check/ top-up
AFTER 1,000 KM
65' Action Engine oil - replacement Hub oil - change Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
(*) See instructions in the Idle speed adjustment section
AFTER 6,000 KM
120'
MAIN - 2
Maintenance
Action Engine oil - replacement Hub oil level - check Spark plug/ electrode gap - check Valve clearance - check Air filter - clean Engine oil - change Driving belt - check Sliding blocks / variable speed rollers - check Coolant level - check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
Maintenance
Action Radiator - external cleaning/ check Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
MAIN - 4
Maintenance
AFTER 36000 KM
270' Action Engine oil - replacement Hub oil level - check Air filter - clean Engine oil - change Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Driving belt - replacement Sliding blocks / variable speed rollers - check Driven pulley roller casing - Greasing Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test
(*) See instructions in Idle speed adjustment section
AFTER 72,000 KM
270' Action Engine oil - replacement Engine oil - change Hub oil - change Spark plug / electrode gap - check / replacement Valve clearance - check Air filter - clean Idle speed (*) - adjustment Throttle lever - adjustment Driving belt - replacement Sliding block / variable speed rollers - change Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Driven pulley roller casing - Greasing MAIN - 5
Maintenance
Action Tyre pressure and wear - check Vehicle and brake test - road test
(*) See instructions in the Idle speed adjustment section
Carburettor
- Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condition. - The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due to wear. - If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor. - It is advisable to replace the gaskets at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
MAIN - 6
Maintenance
the advance degrees indicated by the stroboscopic light. - Check that the advance degrees corresponds with the rotation speed as indicated in the table. - If failures are found, check the Pick-Up and the control unit power supply (positive-negative), replace the control unit if necessary. - The unprogrammed control unit prevents that the engine rotation exceeds 2000 rpm. - The programmed control unit allows the engine to rotate within the prescribed limits.
Characteristic
Variable ignition advance (before TDC) 101 at 2000 rpm
Spark plug
To service the spark plug the engine must be cold, proceed as follows: - Undo the fixing screw of the right side lid on the right rear fairing and remove it. - Remove the spark plug cap. - Use the supplied spanner (with retaining rubber ring) to remove the spark plug. - Disconnect and remove the spark plug cable. - Examine it carefully and replace it if the insulator is chipped or cracked. - Measure electrode gap with a thickness gauge and, if necessary, adjust the gap by carefully bending the outer electrode forward or away. - Make sure the sealing washer is in good condition. - Fit the spark plug, screw it manually and lock it to the prescribed torque with a spark plug spanner.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. REPLACE THE SPARK PLUG AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE. USING NON-COMPLYING IGNITION CONTROL UNITS OR MAIN - 7
Maintenance
SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Electrode gap 0.7-0.8 mm
Electric characteristic
Recommended spark plug CHAMPION RG4HC
Hub oil
Check the oil in the rear hub. To check the rear hub oil level, proceed as follows: 1) Park the scooter on level ground and place it on the centre stand. 2) Unscrew the dipstick "A", dry it with a clean rag and then reinsert it, screwing it tightly into place; 3) Pull out the dipstick and check that the oil level is above the first notch from the bottom. If the oil level is below the Max notch, refill the hub with the adequate amount of oil. 4) Screw the dipstick back in, checking that it is locked in place.
N.B.
THE REFERENCE MARKS ON THE HUB OIL LEVEL DIPSTICK, EXCEPT FOR THE ONE INDICATING THE "MAX" LEVEL, REFER TO OTHER MODELS BY THE MANUFACTURER AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL.
CAUTION
RIDING THE VEHICLE WITH INSUFFICIENT HUB LUBRICATION OR WITH CONTAMINATED OR IMPROPER LUBRICANTS ACCELERATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE SERIOUS DAMAGE.
CAUTION
MAIN - 8
Maintenance
USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOR OIL REPLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY.
CAUTION
UPON REPLACING HUB OIL, AVOID THE OIL COMING INTO CONTACT WITH THE REAR BRAKE DISC.
Recommended products
AGIP ROTRA 80W-90 rear oil hub SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Characteristic
Transmission oil 150 cm
Replacement
-Remove the oil cap A. - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Characteristic
Transmission oil 150 cm
MAIN - 9
Maintenance
Air filter
Remove cleaner cover after unscrewing the two knob screws A and the six screws B, then remove the filtering element. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of compressed air. - Soak with a mixture 50 % petrol and 50 % specific oil. - Drip dry the filtering element and then squeeze it with your hands without wringing.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
Recommended products
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness
Engine oil
In 4T engines, engine oil is used to lubricate the distribution elements, main bearings and thermal group. An insufficient quantity of oil can cause serious damage to the engine itself. In all four-stroke engines, a loss of efficiency in oil performance and consumption should be considered normal. Consumption can particularly reflect the conditions of use (i.e. when driving at "full acceleration" all the time, oil consumption increases). The replacement frequencies provided for by the maintenance programme are defined, depending on the total contents of oil in the engine and average consumption measured following standardised methods. In order to prevent any problems, we recommend checking oil level more frequently than indicated in the Scheduled Maintenance table or before setting off on long journeys. The vehicle is, however, equipped with an oil pressure warning light on the instrument panel.
MAIN - 10
Maintenance
Replacement
Replace oil and filter as indicated in the scheduled maintenance table. The engine must be emptied by draining the oil through the drainage plug B of the mesh pre-filter, flywheel side. furthermore, to facilitate oil drainage, loosen the cap/dipstick A. Once all the oil has drained through the drainage opening, unscrew and remove the oil cartridge filter C . Make sure the pre-filter and discharge tap O-rings are in good condition. Lubricate them and refit the mesh filter and 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. Since a certain quantity of oil still remains in the circuit, engine oil must be added through the plug A. Then start up the scooter, 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.
Recommended products
AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
MAIN - 11
Maintenance
Check
This operation must be carried out with the engine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Make sure the adjustment of the rear suspension is set to the minimum preloading position. 3 ) Screw off the cap/dipstick A, dry it off with a clean cloth and reinsert it, screwing down completely. 4) Remove the cap/dipstick A again and check that the level is between the MAX and MIN marks; top up, if required. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level. Oil top up Always check the oil level before topping up in order to avoid exceeding the MAX level. Restoring the level from Min to Max requires approx. 400 cm of oil.
Characteristic
Engine oil 1.1 l
MAIN - 12
Maintenance
Characteristic
Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm
MAIN - 13
Maintenance
Cooling system
Adding engine coolant. Check coolant level when the engine is cold as indicated in the scheduled maintenance table, following the steps below. Place the scooter on its centre stand and on flat ground. - Undo the screw shown in the figure and remove the expansion tank cap on RHS. - Top up if the fluid level is near or below the MIN level edge. The liquid level must always be between the MIN and MAX level.
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE.
Recommended products
SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16
MAIN - 14
Maintenance
Top-up
Proceed as follows: Loosen the screw B and lift the plastic cover A in order to access the brake fluid reservoir. Loosen the two fixing screws and remove the reservoir cover; top-up with the recommended fluid without exceeding the 'MAX.' mark. This procedure applies to the rear brake pump topup operation; follow the same procedure for the front brake pump. Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance table.
WARNING
ONLY USE DOT 4 CLASS BRAKE FLUIDS. COOLING SYSTEM FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK.
CAUTION
MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN OR CLOTHES. IF THIS HAPPENS ACCIDENTALLY, WASH WITH WATER.
Recommended products
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
Headlight adjustment
MAIN - 15
Maintenance
Proceed as follows: 1. Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pressure, on 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 borderline of the projected light beam should be lower than 9/10 of the distance from the ground to the centre of the vehicle's headlight, and higher than 7/10; 3. If not, adjust the headlight by turning the central screw A underneath the Piaggio badge.
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.
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.
MAIN - 16
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.
TROUBL - 2
Troubleshooting
Operation Inspect the head and/or restore the correct clearance Engine flooded Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to expel the fuel excess taking care to connect the cap to the spark plug, and this in turn to the ground. If the fuel tank is empty, refuel and start up. Automatic starter failure Check: mechanical movement, electric connection and fuel supply, replace if required. Air filter blocked or dirty. 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. Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components The carburettor is dirty; fuel pump or vacuum valve Remove, wash with solvent and dry with comdamaged pressed air or replace Flat battery Check the charge of the battery, if there are any sulphur marks, replace and use the new battery following the instructions shown in the chapter Intake coupling cracked or clamps incorrectly Replace the intake coupling and check the clamps tightened are tightened Defective floating valve Check the proper sliding of the float and the functioning of the valve Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air Fuel pump fault Check the pump control device
Troubleshooting
Incorrect idle adjustment Pressure too low at the end of compression Faulty spark plug or incorrect ignition advance The starter remains on
Possible Cause Secondary air device cut-off valve not working Depression intake pipe of the secondary air device disconnected or dented Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the head pipe
Operation Replace the secondary air device Replace the pipe Replace the device and the coupling
TROUBL - 4
Troubleshooting
Loose nozzles Fuel pump failure Starter inefficient Air filter blocked or dirty.
SAS malfunctions
ANOMALIES IN THE SECONDARY AIR DEVICE
Possible Cause Secondary air device cut-off valve not working Depression intake pipe of the secondary air device disconnected or dented Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the head pipe Operation Replace the secondary air device Replace the pipe Replace the device and the coupling
Insufficient braking
INSUFFICIENT BRAKING
Possible Cause Inefficient braking system Operation Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check TROUBL - 5
Troubleshooting
Possible Cause
Operation the correct level of fluid in the pumps and replace brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc. Failing elastic fittings, plunger or brake pump seals, replace
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.
TROUBL - 6
Troubleshooting
Controls
STEERING CONTROLS AND SUSPENSIONS
Possible Cause Torque not conforming 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. 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. If the front suspension is noisy, check: the efficiency of the front shock absorbers; the condition of the ball bearings and relevant lock-nuts, the limit switch rubber buffers and the movement bushings. In conclusion, check the tightening torque of the wheel hub, the brake calliper, the shock absorber disk in the attachment to the hub and the steering tube. Replace the shock absorber Check the condition of wear of the steering covers and the adjustments.
Steering hardening
TROUBL - 7
Troubleshooting
TROUBL - 8
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
KEY 1. Electronic ignition device 2. Immobilizer aerial 3. Magneto flywheel - Pick-up 4. Diagnosis connector 5. Engine stop switch 6. Voltage regulator 7. Main fuses 8. Plug socket 9. Battery 10. Starter motor 11. Start-up remote control switch 12. Start-up button 13. Secondary fuses 14. Stop button on rear brake 15. Stop button on front brake 16. Boot opening switch 17. Rear boot actuator 18. Saddle opening actuator 19.Electrical actuators control unit ELE SYS - 2
Electrical system
20. Wiring for antitheft device 21. Hazard button 22. Turn indicator switch 23. Turn indicator control device 24.Helmet compartment light switch 25.Rear case light switch 26. Light switch 27. Helmet compartment internal light 28. Licence plate light bulb 29. Rear left turn indicator 30. Rear light A. Stop light bulbs B. Tail light bulbs 31. Rear right turn indicator 32. Front left turn indicator 33. Front light A. Tail light bulbs B. Low-beam light bulb C. High-beam light bulb 34. Front right turn indicator 35.Ambient temperature sensor 36. Remote control headlight 37. Engine oil pressure sensor 38. Horn 39. Horn button 40. MODE button 41. Thermistor 42. Instrument panel 43.Wheel turning sensor 44. Fuel level transmitter 45. Light switch remote control 46. Thermoswitch 47. Electric fan 48. Fuel electric pump control device 49. Key switch 50. Fuel pump 51. Spark plug 52. HV coil 53. Automatic starter Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey ELE SYS - 3
Electrical system
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
KEY 1. Electronic ignition device 2. Immobilizer aerial 5. Engine stop switch 7. Main fuses 9. Battery 49. Key switch 51. Spark plug 52. HV coil
ELE SYS - 4
Electrical system
KEY 1. Electronic ignition device 5. Engine stop switch 7. Main fuses 9. Battery 13. Secondary fuses 26. Light switch 28. Licence plate light bulb 30. Rear light B. Tail light bulbs 33. Front light A. Tail light bulbs B. Low-beam light bulb C. High-beam light bulb 36. Remote control headlight 42. Instrument panel 49. Key switch 53. Automatic starter
ELE SYS - 5
Electrical system
KEY 1. Electronic ignition device 3. Magneto flywheel - Pick-up 5. Engine stop switch 6. Voltage regulator 7. Main fuses 9. Battery 10. Starter motor 11. Start-up remote control switch 12. Start-up button 13. Secondary fuses 14. Stop button on rear brake 15. Stop button on front brake 30. Rear light A. Stop light bulbs 49. Key switch
ELE SYS - 6
Electrical system
KEY 1. Electronic ignition device 2. Immobilizer aerial 5. Engine stop switch 7. Main fuses 9. Battery 13. Secondary fuses 35.Ambient temperature sensor 37. Engine oil pressure sensor 41. Thermistor 42. Instrument panel 43.Wheel turning sensor 44. Fuel level transmitter 49. Key switch
ELE SYS - 7
Electrical system
KEY 1. Electronic ignition device 4. Diagnosis connector 5. Engine stop switch 7. Main fuses 8. Plug socket 9. Battery 13. Secondary fuses 16. Boot opening switch 17. Rear boot actuator 18. Saddle opening actuator 19.Electrical actuators control unit 20. Wiring for antitheft device 21. Hazard button 22. Turn indicator switch 23. Turn indicator control device 24.Helmet compartment light switch 25.Rear case light switch
ELE SYS - 8
Electrical system
27. Helmet compartment internal light 29. Rear left turn indicator 31. Rear right turn indicator 32. Front left turn indicator 34. Front right turn indicator 38. Horn 39. Horn button 40. MODE button 42. Instrument panel 45. Light switch remote control 46. Thermoswitch 47. Electric fan 48. Fuel electric pump control device 49. Key switch 50. Fuel pump
Immobiliser
The electric ignition system is fed with direct current and is protected by an antitheft immobilizer integrated to the control unit. The ignition system consists of: - electronic control unit - immobilizer aerial - master and service keys with built-in transponder - H.V. coil - diagnosis LED The diagnosis LED also works as a theft deterring blinker. This function is activated every time the key switch is turned to OFF, and it remains activated for 48 hours so as not to affect the battery charge. When the ignition switch is turned to ON, the deterring blinker function is deactivated. Subsequently, a flash confirms the switching to ON. ELE SYS - 9
Electrical system
The duration of the flash depends on the electronic control unit program (see figure). If the LED turns off and remains so when switching to ON, check whether there is battery voltage in the electric control unit. Connect the immobilizer tester to the diagnosis socket (see ET4 125 manual) located inside the battery compartment. If the serial LED remains off, proceed to check the control unit supply as follows: - Disconnect the control unit connector and check if: - There is battery voltage between the terminal No. 3 (Red) and the ground connection. - There is battery voltage between terminal No. 3 (Red) and terminal No. 6 (Negative) as shown in the figure. If no voltage is detected, check the wiring to the battery positive lead and see if the 15A fuse is in good conditions. - There is battery voltage between terminals No. 1 and No. 6 with the key switch set to ON and the emergency switch set to RUN If no faults are found, replace the control unit; otherwise, check the wiring and the following components: - Emergency cut-off switch; - Key switch contacts.
ELE SYS - 10
Electrical system
Virgin circuit
If the ignition system has not been programmed, the engine can be started but it will run limited to 2000 rpm. When trying to accelerate, some evident loss of power may be felt. Program the system with the MASTER (Red) and SERVICE (Black) keys as follows: - Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 3 seconds). - Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds. - 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 (Black) service keys can be programmed at one time. Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Once the control unit has been programmed, the control unit is inseparably matched with the MASTER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stored one is deleted. If a service key setting is lost, it is essential to carefully check the efficiency of the high voltage system: Shielded cap resistance ~ 5000 . In any case it is advisable to use resistive spark plugs.
Diagnostic codes
The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings. That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table: ELE SYS - 11
Electrical system
2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial. Ignition disabled-Vehicle immobilised
3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown transponder code. Ignition disabled-Vehicle immobilised
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT
Electric characteristic
immobilizer aerial ~ 7 9 Ohm
ELE SYS - 12
Electrical system
- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case, replace the control unit and then encode the keys. The immobilizer system is efficient when, after switching over to "ON", only a 0.7-second flash is detected (see diagram). In this case, the engine can be started. Example with programmed control unit, transponder, programmed key and aerial working properly. Ignition is enabled (regular conditions of use)
Ignition circuit
Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system. The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.
No spark plug
Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure: - Pick-Up check. Disconnect the control unit connector and check that the cable between terminal No. 8 (Green) and terminal No. 6 (Black) is not interrupted. Check the Pick-Up and its power line:
Electric characteristic
Pick-up resistance value Pick-up resistance value: 105 124 Ohm If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine manual). If non-conforming values are detected, replace the Pick-Up, otherwise check the cable harELE SYS - 13
Electrical system
ness and the connections. In case conforming values are measured and the wiring and connections check is OK, try replacing the control unit (without programming) and make sure the failure has been solved by checking sparks are produced in the spark plug; only then program the control unit. If no sparks are produced with the new control unit, proceed as follows. - HV primary coil check Disconnect the two connectors on the HV coil and check continuity (see figure). If non-conforming values are measured, replace the HV coil. If conforming values are measured, check the wiring. If failures are detected, check the HV coil secondary.
Electric characteristic
High voltage coil primary resistance value High voltage coil primary resistance value: 0.4 0.5 Ohm
HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.
Electric characteristic
High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 300 Ohm
ELE SYS - 14
Electrical system
- Pick-Up. Disconnect the control unit connector and connect the positive terminal to connector No. 8 and the negative terminal to connector No. 6 (see figure). Use the start-up system to run the engine and measure the voltage produced by the Pick-Up. Replace Pick-Up if non-conforming values are measured.
Electric characteristic
Pick-Up voltage value Pick-Up voltage value: > 2 Volt - HV coil With the control unit and HV coil connected, measure the voltage of the coil primary during the startup test with the voltage peak adaptor and connecting the positive terminal to the ground one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.
N.B.
THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE HV COIL PRIMARY IS BLACK AND THE NEGATIVE TERMINAL ONE IS GREEN.
Electric characteristic
High voltage coil voltage value High voltage coil voltage value: > 100 Volt
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.
Electric characteristic
Ohm value: 0.7 0.9 Ohm
ELE SYS - 15
Electrical system
Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.
- With a tester, check the circuit between connections 5-3 and 5-1 is not interrupted. - Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Minimum oil pressure switch check - With a tester, check the circuit between connections 4 and ground (with engine off) is not interrupted. Pick-Up check - Check that there is a resistance of approx. 105 124 at 20 C between connection 6 and the ground lead. - In case values different from the ones stated are detected, replace the defective parts.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
ELE SYS - 16
Electrical system
Choke Inspection
Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If voltage is detected, replace the automatic starter as it is surely failing. If no voltage is detected, connect the multimeter negative terminal to the ground lead and the positive terminal to the automatic starter orange cable; with the key switch set to ON check whether there is battery voltage; if there is no voltage,
ELE SYS - 17
Electrical system
check the wiring connections to the key switch and that the 15A fuse works properly. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed; then check whether there is voltage connecting the multimeter positive probe to terminal No. 5 (Orange), and the negative one to terminal No. 7 (Brown) (see figure). Replace the control unit if there is no voltage; otherwise, check the wiring connections between the starter and the control unit.
ELE SYS - 18
Electrical system
Lights list
LIGHT BULB TABLE
1 Specification High-beam light bulb Desc./Quantity Type: HALOGEN (H7) Power: 12V - 55W Quantity: 1 Type: HALOGEN (H1) Power: 12V - 55W Quantity: 1 Type: ALL GLASS Power: 12V - 5W Quantity: 2 Type: ALL GLASS Power: 12V - 2W Quantity: 4 Type: ALL GLASS Power: 12V - 10W Quantity: 1 RHS + 1 LHS Type: CYLINDRIC Power: 12V - 5W Quantity: 1 Type: ALL GLASS Power: 12V - 5W Quantity: 2 RHS + 2 LHS Type: ALL GLASS Power: 12V - 5W Quantity: 2 Type: SPHERICAL Power: 12V - 10W Quantity: 2 Type: ALL GLASS Power: 12V - 5W Quantity: 1
Low-beam bulb
10
Fuses
The electrical system is equipped with 12 protective fuses for the various circuits on the vehicle, subdivided into two fuse boxes A and B located alongside the battery. The chart shows the position and characteristics of the fuses in the vehicle.
CAUTION
NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIELE SYS - 19
Electrical system
AL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE). BESIDES, IF AFTER REPLACING A FUSE, THE NEW FUSE ALSO BLOWS, THE VEHICLE NEEDS TO BE TAKEN TO AN AUTHORISED SERVICE CENTRE TO IDENTIFY THE CAUSE OF THE FAULT AND AVOID FURTHER DAMAGE TO THE ELECTRIC SYSTEM COMPONENTS OR THE VEHICLE ITSELF.
CAUTION
MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE.
FUSE TABLE
1 Specification Fuse No. 1 Desc./Quantity Capacity:20A Protected circuits:Battery recharge circuit Location:Battery compartment on left side of the vehicle Capacity:15A Protected circuits: Electric fan, battery powered electronic ignition device. Live power supply to load fuses no. 7-8-10-12, light remote control, engine stop switch, automatic starter, electronic ignition device. Location:Battery compartment on left side of the vehicle Capacity:15A Protected circuits: Battery powered plug socket, helmet compartment lighting, electric actuator control unit, antitheft device installation. Live power supply to boot opening switch. Location:Battery compartment on left side of the vehicle Capacity:10 A Protected circuits:Load fuses no.9, battery powered light switch Location:Battery compartment on left side of the vehicle Capacity:5 A
Fuse No. 2
Fuse No. 3
Fuse No. 4
Fuse No. 5
ELE SYS - 20
Electrical system
Specification
Fuse No. 6
Fuse No. 7
Fuse No. 8
Fuse No. 9
10
Fuse No. 10
11
Fuse No. 11
12
Fuse No. 12
Desc./Quantity Protected circuits:Battery powered immobilizer warning light, digital display Location:Battery compartment on left side of the vehicle Capacity:5 A Protected circuits:Battery powered turn indicator control device Location:Battery compartment on left side of the vehicle Capacity:10 A Protected circuits:Live power supply to antitheft device installation, electric actuator control unit, turn indicators Location:Battery compartment on vehicle RHS Capacity:7.5 A Protected circuits:Live power supply to horn, switch light Location:Battery compartment on vehicle RHS Capacity:7.5 A Protected circuits:Live power supply to tail lights, license plate light, instrument panel lightning Location:Battery compartment on vehicle RHS Capacity:7.5 A Protected circuits:Live power supply to wheel revolution sensor, digital display, instrument panel warning lights Location:Battery compartment on vehicle RHS Capacity:5 A Protected circuits:Live power supply to stop lights, start-up circuit Location:Battery compartment on vehicle RHS Capacity:3A Protected circuits:Live power supply to electric pump control device Location:Battery compartment on vehicle RHS
ELE SYS - 21
Electrical system
Dashboard
A = Immobilizer / anti-theft LED B= Speedometer with twin scale (Km/h and Mph) C = CLOCK switch D = Digital display E = Emergency turn indicator warning light F= SET switch G = Rpm indicator H = Fuel gauge I = Warning light for helmet compartment courtesy light on L = Engine control telltale light M = Low fuel warning light N = Engine stop warning light O= Turn indicator warning light P = Low oil pressure warning light Q = High beam warning light Pushing the CLOCK button for less than 1 second displays the following sequence: TIME DATE
To set the clock push and hold the CLOCK button longer than 3 seconds. The numbers showing the hours will begin flashing. Set the hour using the SET button. Push the CLOCK button again and the minutes numbers start flashing. Set the minutes using the SETbutton. Push the CLOCK button again and the day numbers start flashing. Set the day with the SET button. Push the CLOCK button again and the month numbers start flashing. Set the month with the SET button. Push the CLOCK button again and the year numbers start flashing. ELE SYS - 22
Electrical system
Set the year with the SET button. Press the CLOCK button again for 4 seconds to exit the adjustment menu. During the reset process, not pressing any buttons for a period longer than 8 seconds ends the process automatically and the display shows the modified time.
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 regular 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 14.70V -Initial charge voltage equal to 0.3 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 nominal capacity of the battery - Charge time: 5 h
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. CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. 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 THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE, BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL ELE SYS - 23
Electrical system
WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL MARKED WITH THE +POSITIVE SIGN
WARNING
WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
COMMISSIONING A NEW DRY-CHARGED BATTERY - Remove the battery air pipe stop cap and each single element caps. - Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 B) with an ambient temperature not below 15C, until it reaches the upper level indicated on the block. - Tilt the battery slightly to remove any air bubbles formed during filling. - Place the caps on each single element filling holes without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases. - Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes). - Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water; - Before 24 hours elapse, recharge the battery following these steps: - Connect the battery charger terminals observing the correct polarity; - Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity; - Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge. - Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester. - If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging. - Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle. - If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.
ELE SYS - 24
Electrical system
Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart; otherwise, recharge the battery again in the same way indicated above.
PUMP SUPPLY
Specification Key set to KEY ON Engine revs from 0 to 200 rpm Engine revs from 200 to 1200 rpm Engine revs from 1200 to 2000 rpm Engine rpm ] 2000 r.p.m. Desc./Quantity Supply to the pump for 13 seconds Always OFF Always ON 0.2 seconds ON 9 seconds OFF Always ON
Connectors
FUEL PUMP CONNECTOR 1. Ground (White-Black) 2. Live supply (Blue-Black)
ELE SYS - 25
Electrical system
FUEL ELECTRIC PUMP CONTROL DEVICE CONNECTOR 1. Live supply (Blue-Red) 2. Not connected 3. Pump Ground (White-Black) 4. Pump supply (Blue-Black) 5. Ground (Black) 6. Engine revs (Purple) VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Blue) 2. Magneto flywheel (Yellow) 3. Not connected 4. Magneto flywheel (Yellow) 5. Ground (Black) 6. Magneto flywheel (Yellow)
TURN INDICATOR CONTROL DEVICE CONNECTOR 1. Hazard switch (Brown) 2. LHS Turn indicator switch (White-Pink) 3. RHS Turn indicator switch (Blue-Black) 4. LHS Turn indicator bulbs (Pink) 5. RHS Turn indicator bulbs (White-Blue) 6. Battery powered (Grey-Green) 7. Light switch remote control (Purple-White) 8. Live (Orange-White) 9. Ground (Black) 10. Not connected 11. Not connected ELE SYS - 26
Electrical system
12. Not connected ELECTRONIC CONTROL UNIT CONNECTOR 1. Engine stop switch (Sky Blue) 2. Not connected 3. Battery powered (Red) 4. Diagnosis Connector (Purple-White) v5. Live (Orange) 6. Ground (Black) 7. Automatic starter negative (Brown) 8. Pick-up (Green) 9. Engine revs signal (Blue) 10. Engine check warning light (Brown-Black) 11. Not connected 12. Not connected 13. Immobilizer LED (Yellow) 14. HV coil (Purple) INSTRUMENT PANEL CONNECTOR A 1. Not connected 2. Not connected 3. Not connected 4. Not connected 5. Instrument panel lighting (Yellow-Black) 6. Battery powered (Red-Green) 7. Not connected 8. Not connected 9. Not connected 10. Not connected 11. Ground (Black) 12. Live (Grey-Black) INSTRUMENT PANEL CONNECTOR B 1. Speed sensor (Green) 2. Fuel level indicator (White-Green) 3. Thermistor (Yellow-Green) 4. Water temperature sensor negative (Black) 5. MODE button (Green-Blue) 6. Oil pressure warning light (Pink-White) 7. Left turn indicator warning light (Pink)
ELE SYS - 27
Electrical system
8. Right turn indicator warning light (White-Blue) 9. High-beam warning light (Purple) 10. Boot open warning light (Red-Yellow) 11. Rpm indicator (Blue) 12. Ambient temperature sensor (White-Yellow) 13. Ambient temperature sensor negative (YellowBlue) 14. Engine stop switch (Sky Blue) 15. Immobilizer LED (Yellow) 16. Engine check warning light (Brown-Black) 17. Ground (Black) 18. Hazard warning light (Purple-Black) 19. Ground (Ground) 20. Not connected
ELE SYS - 28
INDEX OF TOPICS
ENG VE
This section describes the operations to carry out when removing the engine from the vehicle.
Unscrew the 2 nuts that fix the exhaust manifold to the head and remove it.
ENG VE - 2
Empty the cooling system. Remove the clamps and disconnect the coolant feeding (engine compartment) and return (water pump) pipes.
Remove the holding spring and remove the coolant out pipes;
Remove the holding spring and remove the petrol pump low-pressure pipe from the inlet manifold;
Move the accelerator wire from the throttle control rocking lever; unscrew the set screw and disconnect the transmission from the carburettor.
ENG VE - 3
Disconnect the HV wire from the spark plug; Disconnect the thermistor electrical connection after removing the rubber cap.
Remove the holding spring and move the petrol feed pipe to carburettor; Cut the plastic clamp and disconnect the starter supply connection.
Remove the lower screws fastening the rear shock absorbers to the engine crankcase and the supporting arm;
ENG VE - 4
Cut the clamp on the transmission crankcase duct; after that, disconnect the pipe connected to the air intake on the chassis.
Disconnect the electric connector linking the magneto flywheel to the vehicle cable harness.
Remove the starter motor electrical connections acting on the two screws.
Remove the footrest and the left side fairing; move the lower central cover slightly to the outside and remove the three screws fixing the supporting plate of the swinging arm buffer.
Remove the buffer sealing seeger ring and remove the supporting plate of the swinging arm buffer.
Support the vehicle adequately with the jack. Remove the engine-swinging arm fixing pin by acting on the nut and the pin head as shown in the figure.
ENG VE - 5
ENG VE - 6
INDEX OF TOPICS
ENGINE
ENG
Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Specific tooling
020423Y driven pulley lock wrench
- Remove the cap/dipstick from the engine oil filling hole A. - Remove the ten screws. - Remove the transmission cover. If this operation is carried out directly on the vehicle, remove the cooling air supply coupling of the transmission housing.
Air duct
- Remove the 4 screws and the housing.
ENG - 2
Engine
- To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure.
Specific tooling
020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide
Specific tooling
020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide
ENG - 3
Engine
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED.
Characteristic
Max. value clutch bell Max. value: 134.5 mm Clutch bell 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 (inner diameter 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft assembly on the support to check the crankshaft alignment.
ENG - 4
Engine
- Using a feeler pin 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 support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y009 46x55 Wrench 020444Y010 adapter ring
ENG - 5
Engine
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 TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness 1 mm
BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.
- Remove the four torque server pins and pull the pulley halves apart.
ENG - 6
Engine
- Support the pulley properly using the bell as shown in the figure.
Specific tooling
001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch.
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20 mm guide
Characteristic
Half-pulley standard diameter Standard diameter: 40.985 mm Half-pulley minimum diameter Minimum admissible diameter 40.96 mm Wear limit 0.3 mm ENG - 7
Engine
Specific tooling
020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm
ENG - 8
Engine
- Fit the half-pulley over the bushing using the appropriate tool - Check that the pins are not worn and proceed to refitting them in their slots. - Refit the torque server closure collar.
Using a curved-spout grease gun, lubricate the driven pulley assembly with approximately 6 g of grease. Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This operation is necessary to avoid the presence of grease beyond the Orings.
N.B.
THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; UNDERENG - 9
Engine
TAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER.
Specific tooling
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
Characteristic
Standard length 106 mm acceptable limit after use: 101 mm
Engine
- 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 until it reaches the pulleys maximum opening and place the belt on the minimum rolling diameter. - Remove the driven pulley /belt unit from the tool.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING.
N.B.
Specific tooling
020444Y011 adapter ring 020444Y009 46x55 Wrench
ENG - 11
Engine
Drive-belt
- Check that the driving belt is not damaged. - Check the width of the belt.
Characteristic
Driving belt - minimum width: 21.5 mm Driving belt - standard width: 22.5 0.2 mm
During the wear check foreseen in the scheduled maintenance, check that the rim bottom of the toothing does not show signs of scores or cracking (see figure); otherwise, replace the belt.
ENG - 12
Engine
Specific tooling
020368Y driving pulley lock wrench
Characteristic
Roller: Standard Diameter ENG - 13
Engine
18.9 19.1 mm Sliding bushing: Minimum admissible diameter 25.95 mm Movable driving half-pulley bushing: Maximum allowable diameter 26.12 mm roller: Standard Diameter 18.9 19.1 mm Sliding bushing: Standard Diameter 25.959 25.98 mm Movable driving half-pulley bushing: Standard Diameter 26.000 - 26.021 mm
ENG - 14
Engine
- Correctly refit the previously removed Bendix back to its position. - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread Loctite 243 Quick Set threadlock on the thread and tighten the nut to the prescribed torque. - Avoid the half-pulley rotation with the appropriate stop key tool.. - Rotate the engine manually until the belt is slightly taut.
CAUTION
IT IS EXTREMELY IMPORTANT THAT THE BELT IS PERFECTLY FREE WHEN THE FIXED DRIVING HALF-PULLEY IS ASSEMBLED. THIS IS TO AVOID CARRYING OUT A WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.
Specific tooling
020368Y driving pulley lock wrench
ENG - 15
Engine
Specific tooling
020423Y driven pulley lock wrench
ENG - 16
Engine
Specific tooling
001467Y013 Pliers to extract 15-mm bearings
ENG - 17
Engine
Specific tooling
020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide
With the appropriate tools, remove the oil seal as shown in the figure.
Specific tooling
020359Y 42x47-mm adaptor
Specific tooling
020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide ENG - 18
Engine
Specific tooling
020150Y Air heater support 020151Y Air heater 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020483Y 30 mm guide Assemble the seeger ring.
ENG - 19
Engine
- Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal surface by means of the appropriate tool used from the 52 mm side. The 52 mm side of the adapter must be turned towards the bearing.
Specific tooling
020150Y Air heater support 020151Y Air heater 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020363Y 20 mm guide
N.B.
TO FIT THE BEARING ON THE COVER, SUPPORT THE COVER WITH THE STUD BOLT SET. ENG - 20
Engine
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE.
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
ENG - 21
Engine
ENG - 22
Engine
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REFERENCE PIN AS SHOWN IN THE DETAIL DRAWING.
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CENTRING DOWELS ARE PRESENT.
ENG - 23
Engine
THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 24
Engine
ENG - 25
Engine
- Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket.
ENG - 26
Engine
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The chain tensioning pad must be removed from the transmission side. As regards the lower chain guide pad, 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.
ENG - 27
Engine
- Remove the pins and the rocker arms from the flywheel side holes.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER.
ENG - 28
Engine
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER.
REPLACE THE VALVES IN SUCH A WAY AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.
Specific tooling
020382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020306Y Punch for assembling valve seal rings
Engine
CAUTION
ENG - 30
Engine
REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Characteristic
Rod small end check-up: Maximum diameter 15.030 mm Rod small end check-up: Standard diameter 15 +0.015+0.025 mm
ENG - 31
Engine
- 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.
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
Pin diameter Standard diameter: 56.997 57.025 piston diameter 56.945 56.973 mm Pin diameter: Standard clearance 0.015 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm Wrist pin seat on the piston: Standard diameter 15.001 15.006 mm Diameter of the wrist pin seat on the piston: Standard clearance 0.001 0.010 mm
ENG - 32
Engine
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
ENG - 33
Engine
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.
Specific tooling
020430Y Pin lock fitting tool
ENG - 34
Engine
Specific tooling
020428Y Piston position check support - Set the dial gauge to zero placing the tool on a contrasting surface. Keeping the zero position, assemble the tool on the cylinder and lock it with 2 supplied nuts as shown in the figure. - Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation) - Position the dial gauge on the piston as shown in the figure and measure how much the piston protrudes. - By means of the table shown in the specifications chapter identify the cylinder base gasket thickness to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio. - Remove the specific tool and the cylinder.
N.B.
ENG - 35
Engine
THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSSSECTION. THIS IS TO ACHIEVE A BETTER BEDDING.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
Specific tooling
020393Y Piston fitting band 020287Y Clamp to assemble piston on cylinder
ENG - 36
Engine
Characteristic
bearing A 12.000 - 12.018 mm bearing B 20.000 20.021 mm bearing C 37.000 - 37.025 mm
ENG - 37
Engine
ENG - 38
Engine
Characteristic
Max. wear limit 1.6 mm Valve seat wear Intake guide limit accepted: 5.022 Valve seat wear Intake guide Standard diameter: 5.000 5.012 mm Valve seat wear Exhaust guide Accepted limit 5.022 Valve seat wear Exhaust guide Standard diameter: 5.000 5.012 mm
Engine
lapping compound residues from penetrating between the valve stem and the guide (see figure).
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.
N.B.
Characteristic
Valve check standard length Outlet: 94.4 mm Valve check standard length Inlet: 94.6 mm Valve check Maximum admissible clearance Outlet: 0.072 mm Valve check Maximum admissible clearance Inlet: 0.062 mm Valve check standard clearance Outlet: 0.025 0.052 mm Valve check standard clearance Inlet: 0.013 0.040 mm Valve check Minimum admissible diameter Outlet: 4.95 mm Valve check Minimum admissible diameter Inlet: 4.96 mm Valve check Standard diameter: Inlet: 4.972 4.987 mm Valve check Standard diameter: Outlet: 4.96 4.975 mm
ENG - 40
Engine
ENG - 41
Engine
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).
Specific tooling
020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool
ENG - 42
Engine
- Measure the internal diameter of each rocker arm. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate.
Characteristic
Internal rocker arm diameter: Standard diameter Diameter 12.000 - 12.011 mm Rocker arm pin diameter: Standard diameter Diameter 11.977 - 11.985 mm Cam shaft check: Maximum admissible axial clearance 0.42 mm Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm Cam shaft check: Standard height Outlet: 29.209 mm Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm Cam shaft check: Minimum admissible diameter Bearing A : 36.94 mm Cam shaft check: Standard diameter Bearing B diameter: 19.959 19.98 mm Cam shaft check: Standard diameter Bearing A : 36.95 36.975 mm
ENG - 43
Engine
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.
Assemble the lower 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 chain tensioner slider from the cylinder head side. - Fit the spacer and the screw fastener. - Tighten the screws to the prescribed torque.
ENG - 44
Engine
Fit the pins and rocking levers. - Lubricate the two rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed torque.
ENG - 45
Engine
Insert 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. - Holding this position insert the chain on the camshaft control pulley. - Insert the pulley on the cam shaft while keeping the reference 4V in correspondence with the reference mark on the head. - Assemble the counterweight with the corresponding fixing screw and tighten to the prescribed torque.
Fit the end-of stroke ring on the valve-lifting mass and fit the automatic valve-lifting cam to the camshaft.
N.B.
LUBRICATE WITH GREASE THE END-OFSTROKE RING IN ORDER TO AVOID ACCIDENTAL LEAKS THAT MAY FALL INTO THE ENGINE. ASSEMBLE THE AUTOMATIC VALVE-LIFTER RETURN SPRING. DURING THIS OPERATION THE SPRING MUST BE LOADED AT APPROXIMATELY 180. Assemble the limiting bell using the counterweight fixing screw as a reference. - Tighten the clamping screw to the prescribed torque.
ENG - 46
Engine
Set the tensioner cursor to the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed torque.
Characteristic
Electrode distance 0.8 mm Refit the cylinder head cover, tightening the 5 screws to the prescribed torque. Make sure the gasket is positioned properly. Remove the flywheel cover completely as already described in the flywheel chapter. - Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as described in the lubrication chapter. - Reassemble the driving pulley, the belt and the transmission cover as described in the transmission chapter.
ENG - 47
Engine
FOR SPECIAL SCREWS USE COMMERCIALLY AVAILABLE INSERTS AND INSERT HOLDERS.
- Remove the flywheel cover together with the water pump, the flywheel and the stator as described in the magneto flywheel chapter. - Remove the oil filter and the oil pressure switch. - Remove the cylinder/piston/head unit as described in the cylinder head timing system chapter. - Remove the two retainers indicated in the figure and the starter motor. Before opening the engine crankcase, it is advisable to check axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge. Higher clearances are signs of wear on the supporting surfaces of the crankshaft casing.
Characteristic
Standard clearance: 0.15 0.40 mm
ENG - 48
Engine
- Remove the eleven crankshaft coupling screws. - Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase. - Remove the crankshaft.
CAUTION
KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT. 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 cover shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT, 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 guard on the flywheel side. - Remove the oil filter fitting shown in the diagram
Fitting clearance
Connecting rod axial clearance 0.20 - 0.50
ENG - 49
Engine
- Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crankshaft between these surfaces, as shown in the diagram.
N.B.
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT, MAKE SURE THAT THE MEASUREMENTS ARE NOT MODIFIED BY THE RADIUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS.
Characteristic
Standard clearance: 0.036 0.054 mm Standard dimensions: 55.75 55.90 mm The crankshaft can be reused when the width is within the standard values and the surfaces show no signs of scoring.
N.B.
If the axial clearance between crankshaft and crankcase exceeds the standard and the crankshaft does not have any defect, the problem must be due to either excessive wear or wrong machining on the engine crankcase. Check the diameters of both bearings of the crankshaft according to 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 Standard diameter - Category 1 Standard diameter - Category 2 ENG - 50 Desc./Quantity 28.994 29.000 29.004 29.010
Engine
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 - 51
Engine
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING ENG - 52
Engine
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.
ENG - 53
Engine
- There is only one type of main bushing housing hole in the crankcase The standard bushing diameter after driving is variable on the basis of a coupling selection. - The bushing housings in the crankcase are available in two categories, Cat. 1 and Cat. 2, as are the crankshafts. - The main bushings are available in three thickness categories, identified by colour markings, as shown in the table below. TYPE A B C IDENTIFICATION RED BLUE YELLOW Type "A" Type "B" Type "C" - RED - BLUE - YELLOW Crankshaft half-bearing Bushing category 1.970 1.973 1.9703 1.976 1.976 1.979 Possible fitting
29.025 29.040
Original
29.019 29.034
29.028 29.043
29.022 29.037
Original
Match the shaft with two category 1 crank webs with the category 1 crankcase (or cat. 2 with cat. 2) Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare crankshaft has half shafts of the same category. ENG - 54
Engine
Bushing
B B A C
TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
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.
N.B.
CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE)
Characteristic
Standard driving depth 1.35 1.6 Diameter of crankcase without bushing 32.953 32.963
ENG - 55
Engine
- Insert the filter on the engine with the relative cap. Tighten to the prescribed torque.
ENG - 56
Engine
ENG - 57
Engine
1. Engine throttle recovery 2. Tappet cover 3. Crankshaft 4. By-pass valve 5. Oil filler 6. Oil level in the sump 7. Oil pump 8. Mesh pre-filter 9. Cartridge filter 10. Minimum pressure switch
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD CONDITION.
Specific tooling
020193Y Oil pressure gauge
Characteristic
ENG - 58
Engine
- Install the base of the appropriate tool on the oil guard using the screws provided.
Specific tooling
020622Y Transmission-side oil guard punch
ENG - 59
Engine
- Screw the threaded bar onto the base of the tool and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Use a new oil seal upon refitting. - Prepare the new oil seal, lubricating the sealing lip. - Preassemble the oil seal with the specific 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. - 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. - Use the nut to move the base of the tool until you can feel the end of the oil seal driving stroke. - Remove all of the tool components following the inverse procedure
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. WHEN THE POSITION IS REACHED, DO NOT RETRACT THE OIL GUARD. FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL GUARD SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
ENG - 60
Engine
Specific tooling
020622Y Transmission-side oil guard punch
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 inserting a screwdriver through one of its two holes. - Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain. - Remove the control sprocket with relative O-ring. - Remove the oil pump by unscrewing the two screws in the figure. ENG - 61
Engine
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 clip 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 clip. - Check the clearance between the rotors in the position shown in the diagram. Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure.
Characteristic
Axial rotor clearance Limit values admitted: 0.09 mm Distance between the outer rotor and the pump body Admissible limit clearance: 0.20 mm Distance between the rotors Admissible limit clearance: 0.12 mm
ENG - 62
Engine
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 unit. - Fit the pump cover in the position that permits the crankcase fixing screws to be aligned. - Make sure the gasket is positioned properly and refit the pump on the engine crankcase. The pump can only be fitted in one position. - Tighten the screws to the prescribed torque. - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the belleville washer. Tighten to the prescribed torque. - Fit the oil pump cover by tightening the two screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP TURNS FREELY.
ENG - 63
Engine
Characteristic
By-pass check up: Standard length 54.2 mm
ENG - 64
Engine
ENG - 65
Engine
- Switch the pump to pressure mode (PRESSURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is considered to be normal. If anomalies are detected, replace the pump.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN RUBBER COUPLING AND FILTER OVERHEATING
N.B.
Specific tooling
020329Y MityVac vacuum-operated pump
Engine
the valve opens and the depression is suddenly set to zero. Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it.
N.B.
LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS IN EXHAUST NOISE (EXPLOSIONS IN THE MUFFLER). INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT IN CATALYTIC CONVERTER MALFUNCTIONING
N.B.
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES JEOPARDISING THE CORRECT OPERATION OF THE CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
020329Y MityVac vacuum-operated pump
Fuel supply
- To clean the filtering element proceed as follows: remove the cover and take out the paper filtering element, clean with compressed air and refit. - Make sure the filtering element is in the correct position. - Check that the air passage sections are not damaged or deformed. - Check the correct sealing of the coupling between the filter housing and the cover.
N.B.
FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RESULT IN WRONG VACUUM INSIDE THE FILTER HOUSING, WHICH IN TURN MAY PRODUCE VARIATIONS IN CARBURETION.
ENG - 67
Engine
Kehin
- To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connection, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, and the intake fitting. - Take out the carburettor and rotate it so as to remove the screw with the water joint and the pipes.
N.B.
THIS LAST OPERATION IS NECESSARY SO AS NO TO EMPTY THE COOLING SYSTEM. - Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with the gasket.
ENG - 68
Engine
- Remove the clamp and cover with the airing filter of the diaphragm chamber.
- Remove the 4 fixing screws shown in the figure and the vacuum chamber cover.
WARNING
DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
ENG - 69
Engine
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
- Remove the chamber with the accelerating pump, its control and gasket.
ENG - 70
Engine
- Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
N.B.
Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side. - Remove the float and the plunger.
ENG - 71
Engine
-Remove diffuser.
WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
ENG - 72
Engine
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PROGRESSIONS AND INLET NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.
ENG - 73
Engine
- For maximum circuit, check the air adjustment is correct as shown in the figure.
- For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING. - Check that there are 5 closing ball joints for the operating pipes on the carburettor body. - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear. - Check that the plunger seat does not show abnormal wear. - Replace the carburettor in case of irregularities. - Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
ENG - 74
Engine
- Wash and blow the minimum nozzle properly and reassemble it.
- Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser. - Assemble the diffuser making sure the sprayer is being adequately inserted and lock it. -Assemble the maximum nozzle.
- Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock absorber pin and the return clamp. - Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that there are no fuel infiltration. - Replace it in case of anomalies. - Introduce the float with the rod on the fuel feeding tube side.
N.B.
ENG - 75
Engine
- Remove the drainage screw from the tank, wash and blow it properly and make sure the acceleration pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the acceleration pump valves following this order: INTAKE VALVE (A) Spring Ball Nozzle
IN VALVE (M)
N.B.
THE IN VALVE NOZZLE, CORRESPONDING TO THE ACCELERATION PUMP, IS MILLED. -Check the screw tightness introducing a small amount of fuel in the tank. - Assemble a new gasket on the tank. - Assemble the tank on the carburettor body fastening the 4 screws. - Check that the control roller is free to rotate in its own seat.
N.B.
AVOID DEFORMING THE ACCELERATION PUMP CONTROL ROCKING LEVER. - Wash and blow the flow screw properly. - Check that screw is not deformed and/or rusty. - Assemble the spring on the screw. - Screw the flow screw on the carburettor body.
ENG - 76
Engine
- Adjust the carburettor by turning the screw twice from the close position.
- Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
ENG - 77
Engine
- Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover. - Tighten the screws.
- Wash and blow dry the filter sponge of the ambient pressure intake.
ENG - 78
Engine
- Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws.
Engine
- Check the starter resistance when adjusted to the ambient temperature. With a 12V battery power the automatic starter and check that the piston protrudes as much as possible. - The correct warm up time depends on the ambient temperature. - If protrusion, resistance or timing values are different from the ones prescribed, replace the starter. - Assemble the starter to the carburettor being careful to position the O-Ring correctly, insert the plate with the machined side contacting the starter, tighten the fixing screws. - Position the starter as shown in the figure. - Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE STARTER.
Characteristic
Starter pin travel 10 Starter device resistance ~ 20 Check the automatic starter: Keihin maximum time 5 min
ENG - 80
Engine
THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED. CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 8000
ENG - 81
Engine
ENG - 82
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
This section is devoted to operations that can be carried out on the suspension.
SUSP - 2
Suspensions
- Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch, consisting of adaptor handle, 24-mm adaptor and 15-mm guide, from the opposite side to the brake disc to facilitate removing the disc-brake side bearing and the spacer bushing.
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020412Y 15 mm guide - Heat the bearing seat on the side the brake disc with the heat gun.
- Insert the bearing using the punch consisting of adaptor handle, 42x47 mm adaptor and 15 mm guide, and drive it up to the stop.
SUSP - 3
Suspensions
- Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube - Turn over the wheel and insert the internal spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side installed previously.
- Heat the bearing seat on the side opposite the brake disc with the heat gun.
- Insert the two bearings using the punch consisting of adaptor handle, 32x35 mm adaptor and 15 mm guide, and drive it up to the stop.
Specific tooling
020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide
SUSP - 4
Suspensions
Handlebar Removal
Remove the 3 handlebar covers as explained in the Bodywork Chapter. Remove the handlebar wiring fixing clips and disconnect the electric connectors from the brake levers. Unscrew the fittings, then remove the front and rear brake pump piping. Remove the flexible transmission of the accelerator and remove the throttle. Loosen the clamp fixing the handlebar to the steering tube and pulling upwards, remove the handlebar, then remove the lower plastic cover.
N.B.
SUSP - 5
Suspensions
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING, IT IS ONLY NECESSARY TO TILT THE HANDLEBAR FORWARD ONTO THE FRONT PART OF THE VEHICLE WITHOUT REMOVING THE PARTS FITTED SO AS TO AVOID DAMAGING THE SHAFTS.
Refitting
Carry out the above operations by working in the reverse order from those of the removal.
TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT IT FROM COMING OFF ABRUPTLY
Specific tooling
020055Y Wrench for steering tube ring nut
See also
Removing the front wheel
Overhaul
- With the 10 mm hexagonal wrench for internal parts loosen the upper stem closing cap.
SUSP - 6
Suspensions
- Loosen the stem support clamp and remove fork leg and stem.
- Remove the first spring consisting of 15 windings. - Remove the spring support plate. - Remove the second spring consisting of 21 windings. - Drain the oil. - Separate the stem from the leg by removing the screws with copper washer shown in the figure. To prevent the rotation of the pumping insert a 12 mm hexagonal wrench for internal parts in the stem. - Remove the dust guard ring using a screwdriver as shown in the figure.
- Remove the oil guard safety lock using a screwdriver. - Using the appropriate special tool, remove the oil seal. - Insert the tie rod complete with cable into the oil guard. - Insert the two half rings for diameter 35 mm stems.
SUSP - 7
Suspensions
- Keeping the tie rod in vertical position, insert the bell for the 35 mm stems. - Insert the nut in the thread and take out the oil guard
Specific tooling
020487Y Fork oil seal extractor
Check there are no signs of wear or seizing up between the stem and the leg. If there are, replace the damaged part.
Characteristic
Maximum leg diameter 35.10 mm Minimum stem diameter 34.90 mm Check that the oil holes on the pumping element are not clogged. - Check that the O-ring shows no sign of damage.
SUSP - 8
Suspensions
- Insert a new oil guard with the special adaptor handle and take it to the stop. - Insert the safety clip. - Insert a new dust guard.
- Insert the contrast spring into the pumping member. - Insert the pumping element inside the stem. - Insert the pumping element guide bushing at the lower stem end. - Insert the stem in the leg being careful not to let the stem guide bushing come out.
- Inset and screw up the copper washer to the prescribed torque. To prevent the pumping member from rotating, insert a 12 mm Allen key into the stem. - Pour 125 1 cm of oil into the stem.
Recommended products
AGIP FORK 7.5 W Fork oil Grade 7.5 W - Insert the 21 winding springs, the support plate with the chamfer facing downwards and then the 15 winding spring.
SUSP - 9
Suspensions
- Insert the stem into the fork clamp. - Do up the clamp once to allow the stem closure upper cap to be tightened. - Check that the sealing ring on the cap is in good working order, then tighten the cap on the stem to the prescribed torque.
- Loosen the fork clamp screws and ensure the stem closure cap is fitted properly on the clamp. - Tighten the clamp screws to the prescribed torque.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm adaptor
Refitting
- Grease using lithium soap grease on the roller bearings.
Recommended products
AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2. - Insert the fork into the headstock. - Insert the spacer ring. - Using an appropriate tool do up the first ring nut in the steering tube (upper steering ball bearing). Lock with a torque of 10 13 Nm and rotate the wrench anticlockwise by 90. - Install the space washer. - Using the appropriate tool tighten the second locking ring in the steering tube to a torque of 30 36 Nm.
SUSP - 10
Suspensions
- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steering tube to the prescribed torque.
- Refit the three handlebar covers as described in the Bodywork Chapter. - Install the front wheel. - Refit the brake calliper on the fork leg.
Specific tooling
020055Y Wrench for steering tube ring nut
See also
Refitting the front wheel
ONLY REMOVE THE UPPER BALL BEARING IF YOU REALLY NEED TO. SUSP - 11
Suspensions
Specific tooling
020004Y Punch for removing fifth wheels from headstock
- Check that the roller bearing does not show signs of wear or pricking. In case of replacement, proceed as follows: - Support the fork in a vice. - Insert the contrast plate in the upper end of the steering tube
N.B.
ONLY REMOVE THE UPPER BALL BEARING IF YOU REALLY NEED TO.
SUSP - 12
Suspensions
Specific tooling
020458Y Puller for lower bearing on steering tube
For the version with steering fifth wheel remove the seat on the steering tube by means of the special punch as indicated in the photograph
Specific tooling
020004Y Punch for removing fifth wheels from headstock
SUSP - 13
Suspensions
Refitting
Using the appropriate tool, refit the upper ball bearing and the seat of the lower roller bearings on the headstock as described below: - Place a new ball bearing on the headstock and a roller bearing seat on the lower part. - Insert the tie rod screw of the appropriate tool fitted out with the adaptors for planting the bearing and seat it in the headstock as in the photograph. - Using two 24 mm wrenches, tighten the screw until the seat and the bearing are fully set in place.
N.B.
Specific tooling
001330Y Tool for fitting steering seats
SUSP - 14
Suspensions
- Insert the a new plate and a new dust guard in the steering tube - Insert a new roller bearing in the roller tube. - Using the special tool and a mallet to move the dust guard and the bearing in abutment.
Specific tooling
006029Y Punch for fitting fifth wheel seat on steering tube
- Remove the cotter pin, the cap, the wheel axle fixing nut and the outer one of the two spacers.
- Remove the screws fixing the mudguard and the brake pipe to the bracket. - Remove the screw fixing the brake pipe to the bracket. - Remove the two screws fixing the bracket to the engine. - Disconnect the connector from the wheel turning sensor.
SUSP - 15
Suspensions
- Undo the wheel axle bracket, using the heat gun if necessary.
Swing-arm Removal
- Place the scooter on its centre stand; - Remove the swinging arm/engine fitting shown in the photo - Move the engine back
- remove the spring anchoring the swinging arm to the frame as shown in the photo
SUSP - 16
Suspensions
- Remove the two screws fixing the buffer support bracket to the frame
- Undo the nut on the LHS shown in the figure and remove the corresponding bolt from the opposite side. - Remove the swinging arm.
- Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause excessive clearance on the rear suspension.
Overhaul
- Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side. - Check the axial clearance between the two swinging arms using a feeler gauge
Characteristic
Standard clearance 0.40 0.60 mm Allowable limit after use: 1.5 mm
SUSP - 17
Suspensions
- To check the clearance on the frame-side arm, mount the retainer using the pin fixing the swinging arm to the frame and two adaptor rings of the appropriate tool 020229Y. Alternatively use two washers with inner diameter for 12-mm pins, min. outer diameter: 30 mm: min. thickness: 4 mm.
- Check there is no sticking in the rotation. - Check the axial clearance of the swinging arm on the frame side
Characteristic
Standard clearance 0.40 0.60 mm Allowable limit after use: 1.5 mm - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo.
- Using a suitable pin remove the roller casings as shown in the photographs
SUSP - 18
Suspensions
- Using an appropriate tool plant new roller casings, being careful to position the bearings with the O-rings facing outwards
Specific tooling
020244Y 15 mm diameter punch 020115Y 18 punch
Characteristic
Length of the swinging arm tube on the engine side: 175.3 0.3 mm Length of the internal swinging arm spacer on the engine side: 183 0.3 mm Engine side swinging arm plastic bushing shim: 3.5 0.05 mm Frame-side swinging arm plastic bushing shim: 3.5 0.05 mm Length of the internal swinging arm spacer on the frame side: 290 0.1 mm Length of the swinging arm tube on the frame side: 283 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in the position shown in the photograph - Adjust the bolt as shown in the photograph - Position the frame side swinging arm with the most protruding part pointing towards the silent block side as shown in the photograph
Recommended products
AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2 of the swinging arm
SUSP - 19
Suspensions
- Make sure the silent bloc is not broken. If there is, replace it. - Remove the seeger ring shown in the photograph
- Remove the full silent bloc bracket - Undo the silent bloc ring shown in the photograph
- Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the tool is centred properly on the support
SUSP - 20
Suspensions
- Install a new silent bloc, making sure it aligns properly with the reference tooth. - Fit the silent blocs, making sure the chamfered part of the silent bloc matches the chamfered part of the bracket
- Using the appropriate tool, fit the silent bloc as shown in the photo
Refitting
- To refit, perform the removal operations in reverse. - Grease the bearings and the rolling parts with the recommended grease. -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.
SUSP - 21
Suspensions
the one side and from that fixed to the muffler on the other; - unscrew the two upper nuts (one on each side) fixing the shock absorber spring assembly to the frame and remove the shock absorbers.
Refitting
Carry out the previous operations but in reverse order.
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 bolt from the right side. - Remove the centre stand. FITTING - Install the sealing rings on the support tube of the stand; - Carry out the operations described above in reverse order, then insert the sealing rings into their seats.
CAUTION
SUSP - 22
Suspensions
LUBRICATE THE FOLLOWING PARTS WITH GREASE: SPRING COUPLING PINS, BUSHINGS ON STAND FIXING BRACKETS.
Recommended products
AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2
Side stand
REMOVAL - Uncouple the centre stand return spring; Remove the screw shown in the photograph FITTING To refit, carry out the removal operations in reverse order and comply with the specified torque.
SUSP - 23
Suspensions
SUSP - 24
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
SHOULD THE BRAKE CALLIPER BE REPLACED, BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORTING BRACKET, FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING INSPECTED.
Refitting
- To fit the calliper, follow the above operations but in reverse order.
SHOULD IT BE NECESSARY TO REPLACE THE CALLIPER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER.
Refitting
- To fit the calliper, follow the above operations but in reverse order.
BRAK SYS - 2
Braking system
Refitting
For the fitting, position the disc correctly using the arrow stamped on it as reference. - Do up the screws to the prescribed torque and apply the recommended product
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE.
Recommended products
Loctite 243 Medium-strength threadlock Loctite 243 medium-strength threadlock
Disc Inspection
- Remove the rear brake calliper - Check the disc thickness with a micrometer.
Characteristic
Standard thickness: 5 0.2 mm
BRAK SYS - 3
Braking system
- Repeat the measurement at no fewer than six points on the disc. - Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed onto the brake calliper as shown in the photo.
- In order to be able to anchor the appropriate tool properly use a metal plate with M8 threaded hole and fix it to one of the two rear brake calliper attachment points. - Suitably fix the flange to the wheel axle with the original nut and spacer and a 17-mm bearing
N.B.
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC.
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Max. deviation allowed: 0.1 mm - If you detect incorrect values, replace the disc. If the anomaly persists, replace the hub.
BRAK SYS - 4
Braking system
Refitting
For the fitting, position the disc correctly using the arrow stamped on it as reference. - Do up the screws to the prescribed torque and apply the recommended product
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE.
Recommended products
Loctite 243 Medium-strength threadlock Loctite 243 medium-strength threadlock
Disc Inspection
Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring.
Characteristic
New rear disc thickness 4.0 mm Disc thickness at wear limit (front) 3.5 mm Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm. If a value is measured other than the specified value, remove the front wheel (Front/Rear Suspension chapter) and check the protrusion of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, replace the disc and repeat the check. If the problem persists, check and replace the wheel hub if necessary. BRAK SYS - 5
Braking system
Specific tooling
020335Y Magnetic support for dial gauge
Characteristic
Minimum value 1.5 mm
See also
Front brake calliper
Refitting
To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. BRAK SYS - 6
Braking system
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium-strength threadlock Loctite 243 medium-strength threadlock
See also
Rear brake calliper BRAK SYS - 7
Braking system
Refitting
To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FITTING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium-strength threadlock Loctite 243 medium-strength threadlock
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 COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
Braking system
Front
- Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. - With the brake lever, load the system and bring it up to the required pressure. - Keeping the brake lever pulled, loosen the bleed screw to purge the air in the system. Then tighten the bleed screw - 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 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 COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling
020329Y MityVac vacuum-operated pump
BRAK SYS - 9
Braking system
- Use the appropriate spyglass on the pump to check the level of the brake fluid, as shown in the photograph
- If the level is below the minimum, fill using the two screws shown in the figure - Remove the gasket and fill with DOT 4 until the spyglass is completely covered
CAUTION
MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN OR CLOTHES. IF THIS HAPPENS ACCIDENTALLY, WASH WITH WATER.
CAUTION
THE BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE. THEREFORE, WHEN TOPPING IT UP, AVOID LETTING IT COME INTO CONTACT WITH THE PAINTED PARTS OF THE VEHICLE. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, WHICH MEANS THAT IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THIS WILL RESULT IN INEFFICIENT BRAKING.
BRAK SYS - 10
Braking system
Removal
- Remove the front and rear handlebar covers; - Place a suitable container to collect the oil, disconnect the oil pipe from the calliper and actuate on the brake lever until no more oil comes out; - Disconnect the oil pipe from the pump, then unscrew the two U-bolt clamping screws and remove the pump.
Refitting
- Upon refitting, perform the operation but in reverse order. - Tighten the hydraulic line to the prescribed torque and purge the system. - When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
See also
Front
BRAK SYS - 11
Braking system
Refitting
- Upon refitting, perform the operation but in reverse order. - Tighten the hydraulic line to the prescribed torque and purge the system. - When the operation is over, tighten the brake fluid bleed screw to the prescribed torque.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
See also
Rear - combined
BRAK SYS - 12
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Cooling system
Circuit diagram
COOLING CIRCUIT
Specification A COOL SYS - 2 Desc./Quantity Carburettor heating circuit
Cooling system
Specification B C D E
Desc./Quantity Thermostat with by-pass Expansion tank Radiator Circuit air bleeding
System bleed
- Start up the engine until the operating temperature is reached. - Remove the rubber hood over the bleed valve - Obtain a rubber tube that is of the right length to connect the valve to the expansion tank - Place one end of the pipe on the bleed valve and the other in the expansion tank - Loosen the screw by two turns until the communication hole is revealed with the head as shown in the photo - Wait until only coolant comes out of the rubber pipe so as to eliminate any air bubbles inside the circuit. - Tighten the bleed valve respecting the maximum torque. - Bring the coolant up to the correct level inside the expansion tank
Thermostat Removal
- Loosen the two screws indicated in the figure and remove the thermostat cover. - Remove the thermostat with its gasket.
COOL SYS - 3
Cooling system
Check
- Visually check that the thermostat is not damaged. - Prepare a metal container with approx. 1 litre of water. - Immerse the thermostat, keeping it in the centre of the container. - Immerse the multimeter temperature probe, near the thermostat. - Warm up the container using the heat gun. - Check the temperature when the thermostat starts to open: - Heat up until the thermostat is completely open - Replace the thermostat if it does not work properly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER.
Specific tooling
020331Y Digital multimeter 020151Y Air heater
Characteristic
Thermostat check: opening travel 3.5 mm at 80C Thermostat check: Opening start temperature 69.5 72.5C
Refitting
- Place the thermostat with the bleeding hole at the highest point. - Make sure that the rubber gasket is positioned properly. - Fit the thermostat cover with the connection for the carburettor heating pipe facing the flywheel. - Tighten the two screw to the torque indicated below. COOL SYS - 4
Cooling system
COOL SYS - 5
Cooling system
COOL SYS - 6
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
This section is devoted to the operations that can be carried out on the vehicle's bodywork.
Seat
Raise the saddle Undo the three screws fixing the plate to the central cover and remove the saddle.
Side fairings
Remove the side panel Undo the three clamping screws of the bumper band and remove it.
See also
Side fairings
Driving mirrors
Remove the joint rubber of the mirror housing from the bottom; Unscrew the two screws, then remove the covering from the support arm; Remove the 2 lower retainers fixings the mirror to the frame.
CHAS - 2
Chassis
See also
Front handlebar cover
Instrument panel
Remove the instrument panel support and tip it. Undo the six fixing screws A to remove the instrument panel.
See also
Analogue instrument panel support
CHAS - 3
Chassis
Undo the screw B, then remove the cover C on both sides of the handlebar.
Undo the two fixing screws at the bottom part. Take out the cover by pulling it upwards.
Headlight assy.
Remove the upper cover of the headlight Undo the two upper fixing screws A, the lower screw B and remove the headlight assembly once the connector has been removed.
CHAS - 4
Chassis
For the front turn indicators: Undo the screw C and remove the plastic cover. Undo the screw D and remove the turn indicator once the connector has been removed.
See also
Flyscreen
See also
Seat CHAS - 5
Chassis
Legshield
Remove the front headlight. Remove the three upper retainers.
Remove the mats on the footrest. Remove the ten fixing screws A (five per side) on the shield back plate.
Remove the front mudguard. Remove the six screws B (four per side) fixing the shield with the radiator grille and the spoiler.
See also
Headlight assy. Front mudguard
CHAS - 6
Chassis
Knee-guard
- Remove the front shield. Remove the expansion tank from the shield back plate by undoing the two screws A and fix it to the small front frame in such a way that it does not turn over. Disconnect the connectors of the MODE button and the plug socket. Undo the screw fixing the caps of the two lower screws and remove them.
Remove the three fixing screws to the frame. Remove the instrument panel support. Remove the shield back plate by removing the lower part. To make the operation easier it might be necessary to turn the steering alternately to right and left to free the upper appendages.
See also
Legshield Analogue instrument panel support
CHAS - 7
Chassis
See also
Legshield
Taillight assy.
After accessing the rear glove box, undo two rear light clamping screws D. Once you have removed the rear light, remove screw E and remove the turn indicator.
CHAS - 8
Chassis
Footrest
Remove the frame central cover. Undo the four screws fixing the footrest, two of which are underneath the mat, and remove the footrest.
Undo the two screws A on the internal side of the footrest. Undo the four fixing screws B on the edge of the footrest and remove the lower cover.
The diagram illustrates what to do on the righthand footrest; follow the same procedure to remove the left-hand footrest.
CHAS - 9
Chassis
See also
Central cover
Side fairings
Remove the passenger grab handle. Remove the two upper screws A fixing the side fairings.
Remove the license plate light support then undo the two fairing fixing screws H underneath it.
Remove the rear light unit. Undo the screw C under the turn indicator.
CHAS - 10
Chassis
Remove the five screws D, then slide off the side panel by pulling it backwards to free the teeth hooking it to the central cover.
See also
Taillight assy. License plate light Handles and top side fairings
See also
Helmet bay
CHAS - 11
Chassis
Air filter
Remove the left-hand side panel; Undo the three screws fixing the box to the crankcase; Loosen the hose tightening screw on the carburettor and remove the hose; Push the box upwards to free it from the appendages on the crankcase and remove it ; Undo the clamping screws A (two of which are on the knob-type head) and remove the air-box cover.
See also
Side fairings
CHAS - 12
Chassis
Helmet bay
- Remove the side fairings; - Remove the frame central cover; - Remove the saddle opening receiver from its support by undoing the two screws A on the left fairing; - Undo the four screws fixing the frame upper pipe and remove it once the boot light connector has been removed.
- Open the glove box flap; - Undo the 2 screws two on the bottom of the helmet compartment.
- Undo the 2 screws located in the front part of the helmet compartment.
CHAS - 13
Chassis
- Undo the 4 screws (2 per side) on the sides of the helmet compartment.
- Raise the helmet compartment as much as possible; - Disconnect the electrical connection of the two light buttons; - Remove the glove box flap hook; - Remove the saddle hook; - Disconnect the spark plug HV wire. - Pull the right and left fuse box out downwards freeing the tooth with a screwdriver from above; - Slide off the battery positive and negative leads and the diagnostics socket from the side slots.
See also
Side fairings Frame central cover
Fuel tank
- Remove the central chassis cover. - Remove the footrest. - Remove the three tank retainers. - Disconnect the electric wiring and the fuel pipes.
CHAS - 14
Chassis
See also
Footrest
Front mudguard
Remove the four fixing screws A (two per side) on the mudguard internal side.
CHAS - 15
Chassis
Top-case Rear
- Open the case; - Undo the four screws A to remove the case cover; - Undo the eight screws B to remove the plastic cover;
In order to remove the case support: - Remove the side fairings; - Remove the frame upper pipe; - Undo the ten screws C (five per side) fixing the helmet compartment; - First slide off the rubber rim and then remove the upper cover;
- Undo the four screws D (two per side) on the lower part of the case support; - Pull up the case support to remove it.
See also
Side fairings Helmet bay
CHAS - 16
Chassis
Flyscreen
Remove the driving mirrors; Undo the four fixing screws A and the screw B, then take out the cover.
Remove the four screws C fixing the windshield; Remove the windshield being careful to collect the washers supporting the rubber support blocks.
See also
CHAS - 17
Chassis
Driving mirrors
Undo the two screws A at the side of the handlebar cover and the two screws B on the upper part of the shield back plate;
Detach the cover from the front frame; Remove the two instrument panel connectors; Remove the entire assembly.
See also
Flyscreen Legshield
CHAS - 18
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel.
Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt
Electrical system
Electrical system - Main switch - Headlamps: high beam, low beam, position and parking lights and the respective warning lights - Adjusting the headlights according to the regulations currently in force - Tail light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument lighting - Instrument panel: fuel and temperature indicator - Instrument panel warning lights PRE DE - 2
Pre-delivery
- Horn - Starter
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
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; 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 coolant 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
PRE DE - 3
Pre-delivery
- Abnormal noise
Static test
Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks
CAUTION
Functional inspection
Functional check up: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the frame and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories
PRE DE - 4
INDEX OF TOPICS
TIME
TIME
Time
This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified.
Engine
ENGINE
1 2 3 Code 001001 003064 001127 Action Engine - Replacement Engine oil - Change Engine - Complete service Duration
TIME - 2
Time
Crankcase
CRANKCASE
1 2 3 4 5 Code 001153 001133 001124 001099 002028 Action Crankcase halves gasket Replacement Engine crankcase- Replacement Lubrication by-pass - Replacement Oil seal, flywheel side - Replacement Rear wheel hub - Replacement Duration
TIME - 3
Time
Crankshaft
CRANKSHAFT
1 Code 001117 Action Crankshaft - Replacement Duration
TIME - 4
Time
Cylinder assy.
TIME - 5
Time
HEAD UNIT
1 2 3 4 5 6 7 8 Code 001126 001045 001049 001056 007009 001057 001083 007012 Action Head - Replacement Valves - Replacement Valves - Adjustment Head gasket - Replacement Cylinder / pump rubber coupling - Replacement Thermostat - Replacement Thermistor - Replacement Coolant bleed valve - Replacement Duration
TIME - 6
Time
TIME - 7
Time
HEAD COVER
1 2 3 4 Code 001093 001089 001088 001074 Action Spark plug - Replacement Head cover - Replacement Head cover gasket - Replacement Oil vapour recovery pipe - Replacement Duration
TIME - 8
Time
Oil filter
OIL FILTER
1 2 3 Code 001123 001160 001102 Action Oil filter - Replacement Oil pressure sensor - Replacement Oil mesh filter - Change / Cleaning Duration
TIME - 9
Time
Driven pulley
DRIVEN PULLEY
1 2 3 4 Code 001022 001012 001110 001155 Action Clutch - Replacement Driven pulley - Service Driven pulley - Replacement Clutch bell - Replacement Duration
TIME - 10
Time
Oil pump
OIL PUMP
1 2 3 4 5 6 7 8 9 Code 001125 001051 001042 001112 001122 001172 001130 001129 888133 Action Chain guide sliders - Replacement Distribution belt - chain - Replacement Oil pump - Service Oil pump - Replacement Oil pump chain - Replacement Chain cover flap - Replacement Oil sump - Replacement Chain tightener - Service and replacement Chain cover flap - Check / replacement Duration
TIME - 11
Time
FINAL REDUCTION
1 2 3 4 Code 001010 003065 001156 004125 Action Geared reduction unit - Service Gearcase oil - Replacement Reduction gear cover - Replacement Rear wheel axle - Replacement Duration
TIME - 12
Time
Driving pulley
TIME - 13
Time
Transmission cover
TRANSMISSION COVER
1 2 3 4 5 Code 001096 001135 001170 001132 001131 Action Transmission crankcase cover - Replacement Transmission cover bearing Replacement Air deflector - Replacement Transmission air inlet pipe Replacement Transmission air intake - Replacement Duration
TIME - 14
Time
Starter motor
STARTER MOTOR
1 2 3 Code 001020 001017 005045 Action Starter motor - Replacement Start-up pinion - Replacement Starter motor cable assembly - Replacement Duration
TIME - 15
Time
Flywheel magneto
TIME - 16
Time
2 3 4 5 6 7 8 9
Action Water pump / Pump rotor Replacement Flywheel - Replacement Rotor - Replacement Stator - Replacement Secondary air filter - Replacement / Cleaning Secondary air housing - Replacement SAS valve - Replacement SAS valve / Head connection - Replacement
Duration
Carburettor
TIME - 17
Time
CARBURETTOR
1 2 3 4 5 6 Code 001013 001081 001008 001063 007020 003058 Action Intake manifold - Replacement Automatic choke - Replacement Carburettor - Inspection Carburettor - Replacement Carburettor heating tubing replacement Carburettor - Adjustment Duration
TIME - 18
Time
Exhaust pipe
MUFFLER
1 2 3 Code 001009 001092 001095 Action Muffler - Replacement Exhaust manifold - Replacement Muffler guard - Replacement Duration
TIME - 19
Time
Air cleaner
AIR CLEANER
1 2 3 Code 001015 001014 004122 Action Air filter box - Replacement Air filter - Replacement / cleaning Air cleaner/ carburettor union - Replacement Duration
TIME - 20
Time
Frame
CHASSIS
1 2 3 4 5 Code 004001 004146 004147 004148 004116 Action Chassis - Replacement Front frame - Replacement Footrest support bracket, one side - Replacement Footrest support bracket, both sides - Replacement Rear frame - Replacement Duration
TIME - 21
Time
Centre-stand
TIME - 22
Time
Legshield spoiler
FRONT SHIELD
Code 004020
Duration
TIME - 23
Time
2 3
Duration
Side fairings
SIDE COVERS
1 2 3 4 5 Code 004068 004085 004012 004036 004013 Action Passenger handgrip - Replacement Fairing (1) - Replacement Rear side panels - Replacement Frame cover - Replacement Side bumper- Replacement Duration
TIME - 24
Time
Rear cover
TIME - 25
Time
Central cover
CENTRAL COVER
1 2 3 4 5 Code 004135 004011 004075 004059 004015 Action Fuel tank port - Replacement Frame central cover - Replacement Front mat - Replacement Spark plug inspection flap Replacement Footrest - Replacement Duration
TIME - 26
Time
Mudguard
PARAFANGHI
1 2 3 4 Code 004002 004167 004009 004053 Action Front mudguard - Replacement Grill / radiator cover - Replacement Rear mudguard - Replacement Spoiler - Replacement Duration
TIME - 27
Time
Fuel tank
FUEL TANK
1 2 3 4 5 6 Code 004005 004007 005010 004089 004109 888141 Action Fuel tank - Replacement Fuel valve - Replacement Tank float - Replacement Tank / petrol pump pipe - Replacement Fuel tank breather - Replacement Fuel tank coupling check Duration
TIME - 28
Time
Rear shock-absorber
TIME - 29
Time
Handlebar covers
HANDLEBAR COVERS
1 2 3 4 5 Code 004018 004019 004099 004026 003043 Action Front handlebar cover - Replacement Rear handlebar cover - Replacement Odometer housing - Replacement Handlebar cover - Replacement Steering tube dust guard Replacement Duration
TIME - 30
Time
Handlebar components
HANDLEBAR COMPONENTS
1 2 3 4 5 Code 003001 002063 003061 003059 004162 Action Handlebar - Replacement Throttle control transmission - Replacement Accelerator transmission Adjustment Counterweight - Replacement Mirror support and/or brake pump fitting U-bolt - Replacement Front brake pump - Replacement Rear brake pump - Replacement Brake lever - Replacement Left knob - Replacement Right-hand knob - Replacement Complete throttle control Replacement Front brake fluid and air bleeding system - Replacement Rear brake oil bleeding system - Replacement Duration
6 7 8 9 10 11 12
13
002080
TIME - 31
Time
Swing-arm
BRACCIO OSCILLANTE
1 2 3 4 Code 003081 004058 001072 003080 Action Swinging arm supporting flange - Replacement Silent-block - Replacement Engine/frame swinging arm attachment - Replacement Swinging arm on frame - Replacement Duration
TIME - 32
Time
Seat
SADDLE
1 Code 004003 Action Saddle - Replacement Duration
TIME - 33
Time
Instrument panel
TIME - 34
Time
Locks
TIME - 35
Time
REAR LIGHTS
1 2 3 4 5 6 7 8 Code 005005 005048 005031 005032 005022 005066 005068 005030 Action Taillight - Replacement Licence plate holder - Replacement Licence plate light bulb - Replacement Licence plate light glass - Replacement Rear turn indicators - Replacement Rear light bulbs - Replacement Rear turn indicator bulb - Replacement Rear headlight cable unitReplacement Duration
Front lights
TIME - 36
Time
INDICATOR LIGHTS
1 2 3 4 5 Code 005002 005008 005044 005012 005067 Action Front light - replacement Headlight bulbs - Replacement Front lights cable unit- Replacement Front turn indicators - Replacement Front turn indicator bulb - Replacement Duration
TIME - 37
Time
Front wheel
RUOTA ANTERIORE
1 2 3 4 5 6 Code 002041 003037 003038 003040 003047 004123 Action Front brake disc - Replacement Front wheel rim - Replacement Front wheel axle - Replacement Front wheel bearings - Replacement Front tyre - Replacement Front wheel - Replacement Duration
TIME - 38
Time
Rear wheel
REAR WHEEL
1 2 3 4 5 Code 001016 001071 004126 002070 003077 Action Rear wheel - Replacement Rear wheel rim - Replacement Rear wheel tyre - Replacement Rear brake disc - Replacement muffler/rear shock absorber support arm - Service Duration
TIME - 39
Time
Fuel pump
FUEL PUMP
1 2 3 4 5 Code 004073 004072 004086 004087 004137 Action Fuel pump - Replacement Fuel filter - Replacement Petrol pump depression tube - Replacement Filter / petrol pump pipe - Replacement Pump / carburettor hose - Replacement Duration
TIME - 40
Time
Electric devices
TIME - 41
Time
DISPOSITIVI ELETTRICI
1 2 3 4 5 6 7 8 9 10 11 12 13 Code 005001 005114 005003 001069 001023 005035 005007 005011 005009 005052 001094 002011 002051 Action electric system - change Electrical system - Service Horn - Replacement HV coil - replace Control unit - Replacement Headlight remote control Replacement Battery - Replacement Start-up remote control switch - change Voltage regulator - replace Fuse (1) - Replacement Spark plug cap - Replacement Odometer movement sensor - Replacement Odometer transmission assembly - Replacement Duration
TIME - 42
Time
Electronic controls
COMANDI ELETTRICI
1 2 3 4 5 6 7 8 9 10 11 12 Code 005006 005039 005040 005132 005041 005077 005016 004142 005085 005017 003074 003075 Action Light or turn indicator switch Replacement Headlight switch - Replacement Horn button - Replacement Trunk opening button - Replacement Starter button - Replacement Emergency stop switch - Replacement Key switch - Replacement Plug socket - Replacement Reset button - Replacement Stop switch - Replacement Handlebar right control - Replacement Handlebar left control - Replacement Duration
TIME - 43
Time
Transmissions
TRASMISSIONI
1 2 3 4 Code 002082 002092 002093 002094 Action Fuel tank cap opening drive Replacement Transmission splitter/ hook transmission - Replacement Trunk opening transmission Replacement Trunk splitter/ hook transmission - Replacement Duration
TIME - 44
Time
Helmet bay
PORTACASCO
1 2 3 4 5 Code 004016 005033 004082 005026 005027 Action Helmet compartment - Replacement Glove-box light switch - Replacement Trunk gasket - Replacement Helmet compartment bulb Replacement Helmet compartment bulb support - Replacement Duration
TIME - 45
Time
COPERTURE POSTERIORI
1 2 3 4 5 6 Code 005048 005033 004081 004174 004080 005131 Action Licence plate holder - Replacement Glove-box light switch - Replacement Glove box door - Replacement Trunk levers - Replacement Trunk flap support - Replacement Licence plate light support Replacement Duration
TIME - 46
Time
Front suspension
SOSPENSIONE ANTERIORE
1 2 3 4 5 6 7 8 Code 003051 003010 003076 003079 003048 003002 004119 003073 Action Complete fork - replace Front suspension - Service Fork sheath - Replacement Fork stem - Replacement Fork oil seal - Replacement Steering thrust washer - Replacement Upper steering bearing Housing Steering clearance - Adjustment Duration
TIME - 47
Time
Cooling system
IMPIANTO DI RAFFREDDAMENTO
1 2 3 4 5 Code 007002 007016 007001 007022 007013 Action Water radiator - replacement Fan with support - Replacement Expansion tank - Replacement Coolant delivery pipe - Replacement Expansion tank - radiator connection pipe - Replacement Coolant and air bleed - Replacement Connection water pump pipe / return pipe - Replacement Radiator thermal switch - Replacement Duration
6 7
001052 007019
007014
TIME - 48
Time
Braking system
BRAKE SYSTEM
1 2 3 4 5 6 7 8 Code 002007 002039 002021 002002 002048 002081 002025 002020 Action Front brake pads - Replacement Front brake calliper - Replacement Front brake piping - Replacement Rear brake pads - Replacement Rear brake calliper - Replacement Rear brake rigid pipes - Replacement Brake piping - Replacement Rear brake disc piping - Replacement Duration
TIME - 49
Time
Windscreen
WINDSHIELD
1 Code 004101 Action Windshield - Replacement Duration
TIME - 50
Time
Stickers
TRANSFERS
1 Code 004159 Action Plates / Stickers - Replacement Duration
TIME - 51