Gilera Scooters Service and Repair Manual Models covered Gilera Runner 50 Gilera Runner 50 DD Gilera Runner 50 SP Gilera Runner Purgjet 50 Gilera Runner FX125 Gilera Runner VX125 Gilera Runner FXR180 Gilera Runner VXR180 Gilera Runner VXR200 49.3 cc 49.3 ce 49.3 cc 49.3 cc 128.5 cc 124.2 cc 175.8 cc 181.7 cc 197.7 ce 1997 to 2001 1999 to 2001 1999 10 2004 2003 to 2004 1998 to 2001 2001 10 2004 1998 to 2001 2001 10 2002 2008 to 2004 Gilera DNA 50 GP eXperience Gilera DNA 125 Gilera DNA 180 Gilera Ice Gliera SKP/Stalker 49.3 cc 124.2 co 181.7 00 49.4 ce 49.4 co 2000 to 2004 2001 to 2003 2001 te 2003 2001 tv 2004 1997 to 2004Contents LIVING WITH YOUR SCOOTER Introduction The Gilera Story Page Acknowledgements age 0-8 ‘About this manual _ ~ Page 05 icentfication numbers - Fage 0-0 Buying spare parts Page 06 Safety first Daily (pre-ride checks) Engine oil evel check — four-stroke models Page 0-8 Fuel and two-stroke oll checks Page 0-8 Coolant level check — liquid-cooled models _ Page Brake fluid level check — disc brake models Page 0-10 Tyre checks Page ett Suspension and steering checks Page 0-17 Llagal and safety checks Page Orit MAINTENANCE Routine maintenance and servicing ‘Mode! specifications and service schedules Page 192 Routine maintenance and servicing procedures, Page 1-18Contents REPAIRS AND OVERHAUL Engine, transmission and associated systems Air-cooled two-stroke engines (SKP/Staker and ico} Page 2A+4 Liquid-cooled two-stroke engines (Runner 50, 50 DD, SOSP, Purejet 50, F125, F910 and DNA 50 GP) Page 2861 Four-stioke liquid-cooled engines (Runner VX125, VXRT89, VXRZ0O — and DNA 125, 120) Page 20% Transnission - Page 2041 Gooling system fiquid-coled models) __ Page ori Fie and exnaustsyeiems - Tage et Ignition system - Page Bei Chassis components Frame, steering and suspension a - Page Brakes, wheels and fyres Page Bodywork _ Page Electrical system Page get Wiring diagrams Page 9-25 REFERENCE Conversion factors Pege REF Fault Finding - Pace REF? Index Page REFs14oa Introduction The Gilera by Julian Ryder Story day, the name Gilera means a range of smart scooters styled with the usual Latin fai, but fifty years sco It was {found on the tanks of the most powertu, mos! successful Grand Prix racers of their time. If you remamber the shock waves caused by the launch of the Horida CB750 back at the ‘end of the 1980s, you may think that Honda ‘originated ine high-revving four-cylinder engine. Not 60, It was Gilera. And it was one of their beautiful four-cylinder 800 ec racers bikes that was first to lap the Isle of Man Mountain Circuit at over 100 mph. The marque dominated the world champions in te first half ofthe 1950s, winning the 600 thle every year from 1960 to 1955 with the single exception of 1851. That was down to the genlus of Geoff Duke and the slow but fine handing single-cylincer Manx _Nerten. However, Duke sav which way racing was going and nioved to Glara. The Brivsh press. accused Duke of treachery but he took the nxt threo world titles, along the way he aad the Gira. became ons of the truly great mar machine combinations in the ents history of racing. The Gilera story starts in 1909 The Gilera story actually starts way back in 1908 when a young mechanic called Giuseppe Gilera started making his own bikes in Milan. Things got serious wien he moved ‘fo Arcore i 1820 and entered his bikes in he SOT and some ofthe long-distance races 20 popular ~ and dangerous! ~ atthe time, such 88 the Milan ~ Taranto. ‘The seeds of aroatness were sown in the sid 1880s when Gilera acquired the rights to the Rondine engine fom an aircraft company. This in-line four cylnder was water-cooled ‘and supercharged but tne chases was pretty primitive, With the assistance of one of the ffiginal designers of the Fondine motor, the bike was totally redesigned for the 1948 ‘season. The motor was pivoted backwards 50 that it was. now only incines| 30-degrees Torward. As forced induction was not aiiowed ek oe in the teal world of selfing bikes 10 customers, thegs Were net goad. By {960 tha scooter boom was in full sing and Gilera was i trouti. Howevor, tne company's network of ever 5000 sorvice and etal cutlets wi very attractive propesition for Plagg rmanfasterers of tha ubiquitous Vespa, 2nd in 1989 the 82-year old Giuseppe Gira suis his company. He Gied in 1971 Piaggio investor heavily in small two- strokes, with considerable success. There was an array of very suozessful 50 ce mopeds and rolorcycles a3 via) a8 some truly sporty 1258 including the OX with single-sided swenging arm and singis fork ag. Thera was fever a retury 19 GPS with a brace of 250 ce feed-valve twins. There was also some success with atf-road singles in the Paris Dakar ane other cagert rallies, Also on tne four-stroke front. {he old SsaiLeno model For the 19508 was resurected as a stylish modem 500 0 angio but was 2 commercial Invelavanee. The 68 Ce Norciwest from 1991 seas, hawever, well head of fs time, It used fr Overbared SaluraG motor in a suBerrnate package, but twasn'( enough. Plagijs closed the Arcore factory in 1995, The Gilera brand was now tanstayrad to the sort of scooter thal underpins Plaggio's Success, In the vital allan seoatar market with its hypar-sensitiviy 1a fashion, it you get ‘right you sel by tne Boat-load. Get x wrong and you have a large stock of Doat anchors an your hands. Gilera usualy gat i ight, end in a ‘canny piace of marketing thet traded on the margue's history ney werk racing again 19 2001. Piaggio had Leught Spanish eempony Barbi and thei succaseul 125 oo GP racers, ‘89 they badged one up as a Gilera, hired ‘young Manus) Poggiah ram San Marina as the rider and won the would tie | {you want to eell ecosters in Htaly having ‘an Italian speaking teenage worl ‘champion ting @ bike palntad in ine same ‘colours as Your scoater 8 @ preity good way ‘to go about ‘The question for the immadiate future Is whether Plaggio wil Ieok to eepisit te leaacy cf Gilera’s golden cizesic-ora success by raving thelr efforts ue to the bigger classes, That coud sel alt of scooters.os Identification numbers Frame and engine numbers ‘The frame sofia! number (or VIN (Vehicle Ieentiication Numan) as I offen known) Is stamped Into the trame, and alse appeare an fan identtieation plate; your owner's manual will give exact dotals of is lesion. The fengine number ig stamped into the rear of tha sransmission casing at the pack ofthe engine, Buying spare parts Wen ordering replacement pars, It 16 escontial to identily oxactly the machine for Which the parts are requies. Wale In some cases I's sufficient te kientily the mactine by its tle e.g, “Runner §0', any moditeations ‘made to components mean that itis usuaby fessental (9 idenlfy the socoler by is year of Production, or better stil by ite frame or engine nuinter orth. ‘To identify your own scooter, refer to the €engina ond frarne number refi intarmation in Model spaeiSeahons and service schedules in cr To be lutely certain of receiving the Both of these numbers should be recorded fan Kept in a safe place so they can be ‘uinished to law enforcement officals in the eventaf amet. ‘The frame and engine numbers should also be kept in a handy nlace (such as with your Civing ficence) so trey are always available whan purchasing oF ordering parts for your seocter, Each model type can be Identified by its engine and frame number prefix - refer to ‘Mode! specifications and servica schedules in Chapter 3 ‘The engine number is etarmped into the transmission casing at the ‘correct part, not only is esservial tohave the scooter engine or frame number prefix to hand, but it fs alga usaf to take the old part Jor comparison (where possible). Note that where a modified component has superseded the original, @ vareful chack must bs made that there are no ralaed parts which have also eo" modified and must he used to enable the replacement tobe correctly reitted: where such a situation Is found, purchase al) the necessary parts and fit them, even If this means replacing apparently unworn items. Purchase reolacoman’ parte (rom an authorised Gilere (Plagcio/Vespa) dealer or ‘back of the rear hub: ‘someone who spscialses tn scooter parts ‘they are mare likely 0 have the parts in stock ‘0r Can order them quickly from the imaorter Pattern parts are avaliable for certain ‘components; jf used, ensure these are of recognised guilty branes which will perorrn as well as the origina Expendable items such as lubricants, spar plugs, some electrical components, bearings bulbs and tyres can usually be obtained ai lower prices from accessory shops, motor factors or from specialists advertising in the ational motorcycle press.Safety first! o-7 Professional macharics are trained in safe working procecures. However entnusiastic you may be about getting an wiik the job at hand, take the tere 9 ensure that your safety {snot put at risk. A morn’ lack of attention ‘can resuit in an accident, as can failure to ‘observe simple precautions, There will always be new ways of having accirents, and tho following is not a comprehensive list of all dangers: it 1s ‘rand rather to make you aware of the risks ‘and to encourage a sate approach to il work you carry out on your bike Asbestos © Cerinin fiction, insulating, sealing and other products - such as brake pads, clutch linings, gaskets, ete. ~ contain asbestos. Extieme cae must be taker to avoid inhalation cf cust from such proclucts since it Is hazardous to nealih. It ly doubs, assume that they do comain asbestos, Fire © Remerinor at all times that petrolis highly flammable, Never smoke or have any kind of naked flame around, when working on the Vehicle. But the risk does not end thare ~ a ‘spark caused by an eleciscal short-circuit. by two metal surfaces contacting each ather, by careless use of t00's, or even by static lectricty Quit yp in your body under certain conditions, car ignite petrol vapour, which in ‘a confined space is highly explosive. Never Use petrol as a cleaning solvent. Use an approved safety solvent. © Always isconnect the battery earth ‘erminal before working Gn any part of the fuol or electrical system, ana never risk spilling fuoi on to a hot engine of exhaust © i recommorded that a fre extinguisher Of a type sullable for fuel and electrical res Is kept handy in the garage or workplace at all times. Never try to extinguish @ fuel or Cleotrcal fire with water, Fumes: © Cerin fumes are highly toxic and can quickly cause unconsciousness. and even death if inhaled to any extent, Petrol vapour comes into this category, as do the vapours from eariain solvents such as trichloro- ethylene. Any draining or pouring af such volattio fluids should be done an a well venieted area, © When using cleaning Muids and solvers, oad the instructions carefully. Never use materials {rom unmarked containers - they may give off pisonaus vepou's. 1@ "Never run the engine of a motor vehicle in aan enclosed space such a8 a garage, Exhaust fumes contain carbon monoxide which is ‘extremely poisonous If you need to run the ‘engine, always do son she open al or at least have the rear of the vehicle outside the workplace, The battery © Never cause a spark, or alow @ naked Thtmear the wehicl's battery. tt wil mortally be giving off a certain arpount ot hyerogen ‘which high expose © Always disconnect the battery ground {earth terminal before working on the fuel or lectrical systems (except where noted). © It possible, loosen the filer plugs or cover ‘when charging the battery trom an external source. Do not charge at an excessive rate or the battery may burst © Take care when topaing up, cleaning or carrying the battery. The acid electrolyte, ‘even when diluted, is very corrosive and Should not be allowed to contact the yes or ‘kin, Always wear rubber gloves and gogates tr a face shield. if you evar need to prepare Slectrolyle yoursel!, always add the acid Slowly to the water, nover ad the water tothe ele Electricity © When using an electric power tool inopection ght ete always ensure thatthe appliance is corey connected ‘9 its Plug fn that, where necessary, i's propery Grounded fesrid., Go not use. such Seplances in damp concitions and, agai, Deware of creating ® spark. or applying texcessive neat in the vein of ful or fuel ‘opour Aco eneure that the applances mast ational satty standards iA severe eect shock can result from touching certain pars of to electrical systom, Such asthe spark plug tos (fends) when the engine fe running or being cranked Peviculary components are damp ore Insulation s defective, Where an electronic ignition system is used, the secondary (HT) votage is much higher and could prove fetal Remember... Don't start the oogine without. first ascertaining thet the tranemicsion J In ‘ectra, X Don’t susdeniy remove tne pressure Gap {rot a hot cooing aysiem - cover it wth & Cloth and relesoo the praceure graduslly fret, ‘oryou may get scalded by aseaning coolant X Don’t attemp? to drain al unl you are ‘Sure It has cooled sufielently 10 avoid ‘sealing you. % Don't crasp any part et the engine or. exhaust system without first ascertaining that is coo! enough not to burn you. % Ben't allow brake fluid ar antivaaze to Contact the machine's palrawork or plastlo omnporents ¥ Dan't sipivon toxic liquide euch ae fue, hydraulic fuld or antifraaze py mouth, oF alow them to remain on your skin, 2X Don's iphate cust it may be injurious ‘hsalth (00 Acbostos hoading). x Don't allow any spilled all or graase to ‘emia on the foor ~ wise it up sight away, belave scmeona sips oni. X Don't use tl-titing spanner or other tools which may sip 2nd cause in, % Don't it « heavy component which may bbs bayone your capability - get assistance. ‘Bont rush to irish & job or take “unvertied shor ute, X Don’t allow: childran or animals in or ‘arctind an unattenaed vehioe. XDon't inflate 2 tyre above ths recommended presoure. Apat from ‘ovorsiveosing the carcass, in extrams casoa the tyre may blow off fore. ¥ Do ensure thatthe machine is supported securaly at all times, Thie is especialy importent when the machine is blocked vp 0 ld wheal or fork raroval Do take cars when attempting 10 joosen €@ stubborn nut or bot. It fs generally better to pull on a spanner, rather than push, <0 that # you slip, you fall away from the machine rather than onto ¥'D0 wear eye protection wren using ower tools such a ofl, sander, bench grinder eto. ¥ Do use a barrier oféam on your hands prior t undertaking dirty jobs -.¥t wil ‘protect your skin from infection as well 8s ‘making the dirt easier to femave afterwarcs, ‘but make sure your hanc a/en’t left slippery. Nota that iong-larn contact with Used sngine of can be a neath hazard. ¥ Do keap loose clothing (cuffs, tes etc. 2nd long bait) wel out ef the way of moving ‘rechanical parts. 7Be roryave Hngs, wristwatch #8, bolore ‘Warking on the vance ~ especialy the sectrical system. Be keen your work aréa toy - is only t00 easy 16 fall over articles ‘ert tying around Do exercise Gautian wien compressing springs fr removal of jstafation. Ensure ‘hate tension Is applies and releacod in a ‘contralled manner, sing sultable toole which preoiida ths poelbilty ofthe spring excaping vioirty, 7 Do onsite that ary tng tackle vest has 8 sale working oad ratirg adequate for tie ipa, © Be got someone 20 check penocicaly thal als wel, when working alone on te venice 7 Bo carry out work in 2 logical sequence ang check that everyibing is correctly ‘essemnbied and tightored erwarc Do remember tht your vehicle's oafty affects that of yourseli and ethers. IF in Sioubt on any point, got profetsiona advice, ‘81 zoits of folowing these precautions, YOU ae gnfortunata enough to. injure {yourcel, seek medical attonton ze soon as poste,os Daily (pre-ride) checks Note: The day fore-vie) checks outlined in your owner's manual covers hess toms which should be Inspected on a daily bass. Engine oil level check ~ four-stroke models “The engine has a cipstick an the of ilar op. Unscrew the cap ard wipe ns Cipstick on some elean rag, then insert ine clean aipstck back into the engine and row the cap fly. Before you start: Suppor ihe machine in a1 vit postion ‘On ltt earie stand, Make sur ie on Sve) ound © htase sure you nave a aupy oF te comest Shavaiaba # Chock tno 0 lov! when ta angina isco Wai at wast 8 mutes fine engre he st been ‘Scooter care: {© 17 you have to 20 of frequently, you should heck wihethar you have any oil leaks. i there is no sign of oil leakage from the joints and jaskels Pe engine could ts burning oll due to ‘worn piston tings or failed value otem seals 2) escrow tho esp ~ te el lavel should be up to the MAK ine (aroned. ‘Wrjecese=ry, top up with SAE SW0 API SJ engine cl to being the level up to tw VAX Ine, Do net over. Fuel and THO stroke oil checks 7] Tom the of tank tha sythotc two- Stroke oll designed for motorcycle oil injection systems. Two-stroke oil: # On all two-stroka models check that the fevel warning light extnguishes immediately after the engine is started, I the light stays on Cr if It comes on whist the scooter Is being fiden, the of tark cequires topping-up. ©.D0 not rely on ‘ha oil waming Ight to tel you that the off tank needs topping-up. Get {nto the habit of checking he level of oll in the: oll tare at the game time as you {up with wel @1 tre engine is run without il, even for a shor time, engine damage and very seen ‘angine seizure wilt oceur It te scviad thet a boitie of two-stroke oll cariad in the ‘storage compartment for auch emergencies Fuel: {© This may seem obvious, but check that you ‘rave enougi fue, to complete your journey. If you notice signs of leakage rectify the cause ‘memodiatal. (© Ensure you use the correct grade unloaded petrol (gasoline), minimum @ octane. Note that tha use of unleaded fuel will increase spark plug life and have obvious benefits to tne environment ~ its use is essential on models Ftad with a catalytic converter.Daily (pre-ride) checks o-s Coolant level check — liquid-cooled models Warning: DO NOT leave open containers of coolant about, 2s ie 1s polsorrous. Before you start: ¥ Make sure you have a supply of coolant availabl (a mixture of 5096 dsiled water and 50% corosion iitited ethylene glycol ant ‘note is needed) ¥ Amays chock the cooiant level when the engine is cold ‘Caution: Do not run the engine in an enciosedt ‘space such as a yaraue or workshop. ‘On Rumer models, remove the front panat to check the coolant MAX and MIN level lines, Supper the scacterin an upright position hist chocaing tie vel; make sure itis on level ground. Scooter care: (© Uso ony the spectiad cook! wixture. 2 is importars that ant-trosze is used in tne ‘syst all year round, and not just In the winter. De nat top the Systern up using any water, 98 tne aystam wil bacoe toe cuted @ Do rot overfill the reservoir tank, wich is located behind the front panel on Runner (On DNA models, coolant leva Top-up i necessary with the spectied coolant mature madals and inside the storage compartment fon DNA modes. If the coolant is signficantiy above the UPPER ar MAX line at any time, ne Surplus should be siphoned or drained of 22 prevent the possiblity of Jf being expelled Under pressure, ® Ifthe coolant evel als stoacily. chack the ‘system for uaks (See Chapter !) i vo leaks ‘fe found ane the level continios t tal, e's ecomvronded that the machine « taken fa a Gora diaaer tor @ pressure 19st remove ihe Gooisrt reservoir over to check theovo Daily (pre-ride) checks Brake fluid level check - disc brakes Warning: Brake bydrauie tluid ean harm your eyes and lamage painted! surtaces, sa use extreme caution when handling and pouring it and cover surrounding surfaces with rag. Do not use fluid that as boon standing open fer some me, a8 it absorbs moisture trom the alr which can cause a dangerous loss of braking effectiveness. Before you start: Support the scooter in as upright position. 1% Make sure you have a supply of DOT 4 hydraulic i. Wrap a rag around the reservoir to ensure that any spilage does ot come into contact with painted or plastic surfaces, 4] On Ber models, the brake thi eve Visible through the window in the handlebar cover (arrowed), necessary, remove the reservoir cover or the handlebar ‘cover (se2 Chapter 8) to check the level Scooter care: © The fuid in the brake master cylinder reservoir wil drop sightly as {he brake pacts weer dove. © I ho fluid reservoir requires repeated topping-up this is an Indication of an hydraulic leak someyhe-s inthe system, which should be investigated immediately. ® Check for signs of fluid leakage from the hydraulic hoses and ‘components - If found, rectity immeciatoly. ‘© Check the operation ofthe braka before riding the scooter, i there is evidence of arn tha system (spongy f00 to lover), it must be bled as desoribed in Chapter 7. ‘On CNA ancl ice models, ths window isin the side ofthe roservow. 1h iva is below te MIN vel ne, Temove the two reservoir cover screws ‘and remove the cover, the diaphragm plate anc the diaphragm. On Runner models, first remove the front handlebar cover (9e2 Chapter 8) “Top-up with new claan hydraulic fluid of the recommended type, unt the lovet is ‘above the MIN mark. Do nel overt] anc take care to avoid spills (2ee Warning above), Enoure that the diaanrag is correctly seated before installing the plate and Cover, then tightan the scrows SecurelyDaily (pre-ride) checks o«11 Tyre checks The correct pressures: ©The tyia8 must Be checked! when cold, not immoiatay attr feng. Not fet ow re presaures may cause the tro slip onthe Tio. ome ef fh 8 prossures wl cause abnormal tread wear Sn untae Hnd'ng. Ue an acourate pressure gauge © Proper air passure wi increase tyre Me and provige maximum Stably an vie comin © Fer to Med! specications in Chaotar 1 for the correct tyre reser for your sect. Tyre care: © Check the res caret for ets, tears, embed nals a ther Sharp objects and excessive wen Operation of the scooter wth xeesewvely worn Vien i extremely hasargous, a= eaction and fanding are rect afactes 1 check he condtion of the ye valve and ensure he dst cap in Face Te & ‘Check the tyre pressures when the tyros {are cold and keep them properly inflated. Maasure tread capth at the centre of the tyre using a tread dpi gauge or ruler. ® Pick out any stones or natis which may have baccms embedded in ‘the tyre trea. left, they will eventually perctrato tough the easing: and cause a puncture, © Ii tyre damage 's epparent, or unexpiainee \oss of pressure ie experienced, s2ek the acvine fa ire iting Specialist without delay, Tyre tread depth: © At the time of writing KC law requires that tress depth on machines: Set $0 ce must be at least imu over 8/4 ofthe tread bread al the way around hei, wh o ble atehes fee MOT Yas! Gc lathe Reference secon. Many rider, owaver, consist 2 rm read Gath Finn to bea star lent. {@'"For machines wth an engine size not greaier han 80 ee, UK aw States tha treed dapth may be loss inan Yen f the vend pater Steariy visve across the whole ofthe wae breath al it way stout theyre (©. Many tyres ow incxporaio wear Incatore in the vend Want the trangular pointer on the tyr sca to locale ths insinator bat fand replace tro tyre tho teed has wor dow to tha bar t. ‘Tyre tread wear Incleator bar and is Jocation marking usualy ether an arrow, 2 wisagle of tha jotters TW) on the sidewal (arowed), Suspension and steering checks © Check that the front and rear suspension @ Check that tho rear suspension is ‘operates smoothly without binding ‘dusted as required. © Chock that the stesting moves smosthiy from lock %9 420k, Legal and safety checks Lighting and signalling: © “Taka a minute to check that te hoadlig tal ght, bake gk, instrument gris and turn sia al work correct. ‘Check a ha Rom sounds wan tho son fe operated A working speecometer graduated in mph is a statutory fecnrernart inthe OC Safety: © Chock that the trettle grip rotates emocthiy and snaps shut wien Teossed val stoe'g postions. {9 Chock that the sian return apting hols the stand securaly uP ven retracted (© Check that both brakes work corecty wien aoplied end tee off ‘men releNotes oei2Chapter 1 Routine mainten 199 ance and servicing Contents A filer an rarssiesion fier deening ©1)- Headlight an check and adjustment 6 Bute check : 2 idle ichoven spood check ard adustinert " Bate Stor checks © 8 Nitwend bots ighness check % Brave cote arsine check sd ivcascn~ Guin ea bake. 4 Ol pup dive bet rnawal two soko aging 48 Brake fad ceerge = dee 5 Secondary airoysterm clean two-stroke gine 2 Brake hose rove Brake. & Spare pus gap chock and alusiment 3 Bist lover pot bican 7 Sparc pla renewal = ae Brake shos/oacoviens check : 8 Speedometer cabo and arive Gear hbeation 238 (oolng sje check hacked erg 9 Sieerng hoad bearings check andl adjstment a Goslertchenge = iaud-oclee ange 19° Suoponsion check» 25 Dine bet inspacton snd rel Trot cane nd ol pimp chock and asian: 26 Engi olan change fas oto 12 Vale cuarances check and agusiment four stoke engine |... 27 Fu ojeor aor erawal saowsureeer et 413 Vanator ne euth check 28 Gero ool rect + 14 Woes and res cheek 29 Gearon ol ange 15 Degrees of difficulty ‘Faity easy, suitatle Os | Feiny ificut, “Dy | Difficult, suitable for & ‘Very difficult, xs ebeginner wih = SS siatle fr compet & | exoeisiced DIY S| suatieforempet DY SQ | someepaierce = SY] Drvmeotanic SN | mechanic | cr protessiona Introduction 4 This Craptar ls elesignad 19H the hore Imachavve maintain hi har easter for safety, ‘economy. long lite und peak perormance. 2 Decicing where (© start oF plug into the service schedulo depends on sevaral factors I the warranty period on yaur scooter has at expired, and If iL has been rmaimained according to the warranty standards, you may want to pick up routing maintenance ae it aineldes wth tha nox mieage or calendar interval, I you have owned the maghine for Some time Dut nave never performed eny rmantenanes on [then you may want to star at ine nearest ‘terval and Include some aditiona) procedures te ensuve that sodring Important is overlooked. Ifyou have Juct had & ‘major engine overhaut, then you may want to start she muainienmiee rowne (rom ths beginning. I you have a used macnine and have no knowlege of iis hietory oF maintenayice record, you may desire to Note 1: The daily (orecride) checks dttiled at combine all the checks into one lstge service ihe beginning of this Manual cover those intially and then settle into the maintenance soneculs prescribed. 8 Befera beginning any maintanance o¢ the Machine should be cleaned therouphiy, especialy ound the srgine are ‘ranermission covers. Cleaning wih nae ensure ‘hat dit does rot cortamimata the argne end ‘wil allow you to detect woar and damage tat could orherwlve easily go unnoticed 4 Sorcin maintonance information ig sometimes printed on dacats aitarhed to the scovter. Ii the information on the decals differs fiom that nckided here, use the information on tre decal 5 Al) the fourstiok® enginad seooters covered f this sranual ave fired witht four- valve, liuic-coolec LEADER fLow Emission ‘Advanced Engine Range) engine. items which shod be inspacted on a daily basis. Aways perform the pre-rie inspection ‘at avery maintenance interval (i adeition 10 the procedures fstech, INete 2: The intervals listed on the following ‘pages are the intervals recommended by the ‘manufacturer for each particular operation turing the model years covered in this manual. Your owner's manual may have ‘liezent intervals for your moda Nate 8: An initial (one-off) service wit! be pestormed by 2 Gira dester after the frst 600 rmlas (1000 km) from new. Thereafter, the scooter should be serviced accoreing to the intervals specified in the service schedules which folow12 Model specifications and service schedules ee Gilera SKP/Stalker eee Model identification Engine 49.4 ce single linger air-cooled two-stroke Transmission Variable speed automatic, belt ivan Ignition... a Bloctronic ‘Suspension: Front LUoside-down telescopic forks Rear ‘Swingarm and moroshock Brakes Single disc (oni), drut or disc (rear) “Engine no, prefix 2013 Frame no. prefix ZRBC 180 Wheelbase 1230 eam Overall engi 4760 mm Overallwidth 720 ro Seat height 2 810mm Kerb weight 87 KG Fuel tank capacity: Total. - 8.0 O95 Reserve AS ies Introduced 1997 Servicing specifications and lubricants Spark plug type ‘Champion N2C ‘Spark plug #lectrode gap 05 t0 0.8 mn {ote speed... ‘1800 to 2000 rpm Tyre size: Front = 120/90-10 Rear 1308010 Front tyre pressure 175 psith2 Ba) ‘ear tyre pressure: Rider only 24 psi(1.6 Bar) lder and passenger 23 psi (20 Ba) Fuel type Uniesded pect igasatine) min 96 octane Engine oil ype Syntnetc two-stioke ol fr injector ‘systems, APITC of niger Engine ol ank capac Total 12ires Roserve 2a tte Gearbox ot 02 [B080 API GL3 gear of Gearbox off quantity approx. 75.00 Brake Muid 7 DOT 4 Air fter oil 550% air itr 3 and 80% petra gasoline) Variator .--- LLihsum soap grease (NLGI3) ‘Speadometer drive gear -Lithium soap grease (NLGI3) Brake lovers Calcium soap grease (NLGI 1-2) Control cabies [Motor cil or cable fubricantModel specifications and service schedules 1-3 Service intervals - Gilera SKP/Stalker Note: Always perform the Daily (pre-ride) checks before every service interval ~ see the beginning of this Manual Tertsectinin | Every s000km | Every 10,000 Km | Every 15,000 4m ‘is Chastor (000 mies) {6000 ries) {9000 mies) or 12 months or? years ord years ‘Air filter - clean 4 v - Battry ~check 2 “ Brake system chock 3 ¥ Srake cable = check ane hieation 4 v | Stake nud chango 5 a Sako hos — renew 6 “ Brake lovers — lubrication 7 v Sake pads/shoes — wear chock 8 ¥ Drive bel ~ check " Gearbox cil lve = check = 1% v _ Gearbox ail =chonge 16 v | eaight aim ~check and acnusment 6 “ 1 spe0d ~ chock and adustment 7 Zz Z | Nuts and bots tahiness check 18 ¥ i. Oi pum eve bt racow 19 20,000 km/ | 12,000 mites Secondary ai system ~ clean 2 y | (modo with catalytic converter Spark pg ~ gap check, adjust or renew 21 v Speedometer cable and drive goa = ibrication 23 ¥ Steering head bearings ~chack and adjstmant 26 v Suspension=check 29 v ‘Tirole cable pump — check and aeustment 25 v Varator and cute ~ check 23 7 varator ¥ elton Whee's and tyres general check 29 | ” "Tho brake fuid must be changed every 2 years and the brake hose renewed every 3 years, respective of mileage.14 Model specifications and service schedules | | Gilera ICE Model identification Engine 48.4 ce single cylinder eir-cooled two-stroke Transmission \Varite ened automatic, bet criven Ignition Electronic Suspension: Front cose Telescopic forks Rear ‘Swingarm and manoshock Brakes «Single cise rom, drum (ear Engine no. prefie . C30M Frome no. profix ZAPC 300 Wheelbase . 3220 mn Overall engin Sn 4710 mm Ovorall widely 2.2. * a 380 m0 ‘Seat height 380. 92 kg 65 tres 1.2 hres Invodticed “2001 Servicing specifications and lubricants | ‘Spark plug type Champion RN2C ‘Spark plug electrode gap 281007 mm Idle speed 1700 to 1900 ram “Tyre size 120/90-10 Front tyre pressure 185si(1-3 Ban) ear tyre pressure 26 psi (1.8 Ber) Fuel ype |... ‘Unieaded potol (gasoline) min 35 octane Engine al! type ‘Synthetic hwn-strake oi for injector ‘systems, APITC o”highor Engine oil tank capacity: Total 1.6 Hes Reserve 0.4 ite Gearbox ail type BOWad API GL3 gese ol ‘Gearbox off quantity . approx 75.60 Broke fluid DOTS Air fit el $5096 air fter oi! and 80% petal (gasodns) Speedometer drive gear —-........ Lithium soap grease (NLGI3) Brake levers -----ece0. {Calcium scap grease {NLGI 1-2) Control cables ‘Motor olor cattle lbicantModel specifications and service schedules is Service intervals - Gilera Ice Note: Always perorm the Daly (pre-ide) enecks bevore avery service interval - soe the beginning ofthis Manual Tecescionn | Emon | Gry 1o000%0 | any 150001 ‘this Chapter (3000 miles), {6009 miles), {9000 miles) Sri | Save | Genoa ‘Av fier ~ lear 1 v ‘tay whee Z ’ - Sedans 5 o 7 fk cabo chech abc i 7 _ Be change 5 z Be psa one ¢ - _- ic natin z 7 | Sinks priahnonccsvetaoc a v Dive ew 1" z ‘Gearbox oil level —-chack 14 v | Seaton = charge 2 | tush in ~ chock and agusmen ss v ~| ii sped check and eae ” 7 Seconny erayten clan = : toa teomgy are | _ Se grew = - serine ea 2 z hig aig tek ond 7 > — ‘hie cick aa - % ~ ry a = War ak anes 2 ¥ hia ta ey 2 oar i! PS onl oy a pow eaiolbe at op,+6 Model specifications and service schedules Gilera Runner 50, Runner 50 DD, Runner 50 SP Model identification Engine 48.3 66 single cylinder Uauid-cooted two-stoke Transmission arable see automate tk ven lgntion Electronic Suspension: Front _Upside-down telescopic forks oar Suingarm ge monoshook Brake Single ie (ent), drum tear ~ Single ie rot and rea) cia ZapC 140 1280 ror 1789 morn 720 mm Seat height S sisi Kero weight: ‘Runner 60 28%9 Punner DOIS® 93h9 Fea! an capaci Total B5iires Reserve 15itres Introduced: Runner 50 sd Runner DDS? 1993 Servicing specifications and lubricants Spark plug type = Champion N86, NiG or RNTG Spark lug oexroao gan 051mm lele speed “1800 te 2009 ron Tyre size: Front s20770-12 Roar 190770612 Front tyra pressure 23 poi (1.6 Ba) Rear tyre pressure: Rider enly 25 51 (1.8 8a) Rider and passenger 29 psi (2.0 Bar Fuel type Unleaded pair! (gascline) min 98 octane Engine ol! {ype “Synthetic two-stroke oil for injector systems, APITC or higher Engine oll tank eapacity: Total... Reserve Coolant type «»- 5056 csicd water ere S03 etiyiow aye artteeze Cooling systam capacity approx. 0.9 ire Gearbox oil type -- .801N90 API GLS gear ot Gearbox oil quantity ‘appr0%. 75.06 Brake Maid | Dor Ai filter oi) £503 i fiter oi and 0% patel gasoline) Varator Lithium soap grease (NLGI 3) ‘Speedometer drive gear “uthium soap grease (NGI 3) Brake levers... Calcium soap grease (NLGI 1-2) Control cables Motor olor cable tubricantModel specifications and service schedules 37 Service intervals - Gilera Runner 50, Runner 50 DD, Runner 50 SP Note: Always perorm the Dally (pre-ide) checks bafare every service interval see the beginning of this Manual Textsectionin | Every s000km | Every J.cnkm | Svery 16,000 en ‘hs Chaptor {00 mies) ‘6200 mies) (000 mies) or 12 monte or? yours 3 years Aiiter= cian 4 y Batery check 2 ve - wiewe sytert— ene 3 v Brake cable Funns 50)~ eneck ane lubrication ‘ _v rake fie ~ charos 5 ” Brake no80~ one 6 v Braka vers — hibition 7 Brake pad/shoes — wear check a v oolng system —checke ® ’ Coolent= change _ 10 _ Dive bot cheekrenew " ¥ (G2erb0% o evel ~ oboe ” v : Gearbox of = ohange 15 = ¥ a oacight am = chock an asint 16 v in spond check and acustrent 7 v ‘us ad els = ghinass cheek 8 : v © pump drive bet renew 18 20.900 tend zon mise Secondary ar system ~clean 20 v (modes wit caste converte) — Soak oh —reree 22 ¥ ‘Sposdometer cable and dive gear lubrication | 20 ’ elustent 4 vo : 2s ¥ : “Thre eablool pump ~ check and adhustent 2 ¢ Yariator and cltch check 8 ¥ hoes and tyres gener! check 20 « * The brake fluid must be changed every 2 years arc’ the brake hase renewed avery 3 years, iespecive cf mileage. ” The coolant must be changed every years, trespective of mileage.+8 Model specifications and service schedules Gilera Runner Purejet 50 Model identification Engine 49.8 oc single cylinder liquid-cooled two-stroke “nih "Purejet fue! injection ‘Transmission Nariable speed automatic, belt driven Ignition vee lectronic: Suspensi Front Upsicie-down telescopic forks Roar ‘Swingartn and rnonoshock Brakes: ‘Single dise (hont and rest) Engine no. pretix = ZAPC 36181 Frame no. prefix ‘ZAPC 3610 vrneelbase 4290 arin Ovorail length “1800 mm, ‘Overall wicth| Tom ‘Seat height 830 mm Weight tor) 29 kg Fuel tank cana Total 12.0 tres Resarva fi Boies totredluced 2003 Servicing specifications and lubricants ‘Spark plua type ‘Chamsion AGS YOR, Spark plug electrode gap». 108 100.7 nye {lo apace 2000 79m Tyre size: Front oaor70-12 Rear * 190/70 12 Front tyre pressure Sys 8B) Rear tyre pressure 2.1 25 pal {t.2 Ban Fuel typos. \Utieded pettotigasoins) min 98 octane Engine of woe Syntietc two-stroke 0! fr injector ‘systems, AP! TC or higher Engine oil tank capscity. ‘Total 1.8 Wires Rosorve To tes Coolant type... 50%6 ciated watw and 80% alryiore qyesl ant feoze Cooling system capacity Siena. approx. 0.9 es, Gearbox oll typ .- N80 API GLB. gear cit Gearbox oi quartty “approx. 78.68 Seake fluid .. . “bor4 Air fitor eit “BOY air ie’ OF and 5056 petrol (gaecling) Speedometer arive gear Lithium soars grate (NLG!3) {Galcium soap grease {NLGI 1-2) Motor ei or cable iubricant Brake levers Conttol cablosModel specifications and service schedules : Service intervals - Gilera Runner Purejet 50 Note: Aways perform he Dail fore-rice) chozks betore every service interval - ss (he bovinning ofthis Marual | atsecionin | Every 000km | Evy t.0KM | Every 1.000 ¥en this Chapter 3000 miles) (6000 mites) {2000 rmiles) | ortzmonts | Sreyens ayes | Arer=eiean T 1 ( v Battery ene 2 v4 | rake aystem ~ chen 3 { vt | Brake ns change 5 v | Be tose rene . { = es 7 ZI - ‘Brake pads - wear check 8 ¥ | Caving system ~ check @ «| | cootant— change 10 “ | Drive belt— rer 1 rune fer 19 Goon —_ wf - Gearbox ot cmange | se | I v | oadtignt aim - etecie and adjustment 16 i v | nase tpn Ts | | ott pume cre batt ~ renew 19 20.000 «mi | 0 reco res Secoraay at ston 2 v Sar pu renew 2 v aI Speedometer cable and drlve gear — lubrication 23 « | Sarnatimid teat checkencaaring | __—_ Be - _v | | suspension - check _ 5 _ _ | v Tht blot pun = check and ator om Te Vator and clutch oh 2 __ vite vouch ‘Wests and tyres — ganeral chack 23 v — J * The brae foie must be changed every 2 years and the brake hose senewed every 3 years, kvespective of ieaze. Tha ceolant must be changed every year, veapectve of milage,i110 Model specifications and service schedules Gilera Runner FX125 and FXR180 Model identification Engine « 328.5 cc and 175.8 ce single cyinder tquld-conled two sr0ke ‘Transmission aril speed aarat, ba ven fanition Fiectronie, Suspension: Front. -Upside-cown telescopic forks Rear ‘Swingatte and adjustable monoshock Brakes os. ‘Single se (front. cum oF Gise (reer) Engine ne. profix: Fxizs MO 73M FKRIB0 MO Bie Frame no. prasic~ Px: Front dise, rear drum brake madel ZAPIA 7a Front and rear dise brake model . say @9)ZAPM O70 ‘Frame 00. profix - FXP1B0; Front dise, rear drum brake modi <. ZAPM 080 Front and rear disc brake modo| Wheelbase + Overall length... ‘Overall width Soat height . Korb weraht Fue tani capacity (88 model ‘Tatas Roserve Fuel tank eapacity (1900-0n modale): Total arte! 2.0 tres Reserve 30 ftres Introduced 1098 Servicing specifications and lubricants Spark plug type ‘Champion RNZC Spark plug electrode gap 0.61907 mn Idle speed 1400 to +609 rpin Tyre size: Front s20r70-12 Roar (1908 mada). 490/70-12 ear (1989-0n models) -- 130/60-13 Front tyre pressure . 0 psi (1-4 Bar) Rear tyre prose Rider only 23 psi(1.8 Bar) Rider and passenger £23 10 32 psi 2.0 102.2 Bar) Fusl type. LUnleaced petro} (easoine) min 96 octane Engine oil type ‘Synihstic two-stroke oll for njector ‘syste, API TC or higher Engin cil tank capaciyn “Total 1 Bites Reserve 2a ios Coolant type «5034 dati water and 80% etme gol ant-teeze ‘Cooiing system capacity 8PON Tres ‘Gearbox ol ype = 20090 API GL3 gear oi Gearbox eer “ABpFOX. 80 co Brake uid DOTS Ai iter oi 50% ai ftor of ar 80% petro gasoline) Variator Lithium soap grease (NLC! 3) Speedometer drive gear = Lita soap gress INLGL3) Brake lovers Gale soap grease (MSI 1-2) Control cables Motor olf er eable borcantModel specifications and service schedules :-1: Service intervals - Gilera Runner FX125 and FXR180 Note: Always periovm the Daly (pre-ride) checks before every service interval - see the beginning of this Maruat Toxtsectionin | Evoyso00Km | Every ‘0.000 xm | Every 16.000 hm this Chapter 18000 miles) (5000 mites) (9000 rites) or 12 months ‘or yeers or youre ‘ir fiter ~ lean 4 _ y | Battery ~ check 2 ¥ 7 rake system ~ check 3 v Brake cable - check and tubrication 4 v / Brake fd ~ change 5 a “ rake hose - renew 6 Brake levers — lubrication 7 ¥ [ _| Brake pads/shoos wear check a v Cooling system ~ check ® ¥ es Cooling system ~ draining, flushing and retting 10 we Drive bolt renew _ - v Fuol system ~ renew fiter 13 20.000 km a 12,006 miles ‘Gearbox oil evel ~ check 4 v Gearbox il change 15 ¥ Headlight im ~ check and acustment 6 v Ile speed — check and adjustrent 17 | v Nuts and botts~ tightness check 18 | v - ‘Ol pump deve bolt ~ renew cy {80,000 km? | 7 18,050 miles Spark plug ~ gap chock ard aglustment ‘Spanien =i L ‘Sposdometer cable and drive goar~ lubvication 23 v ‘Steering head basrings ~ check and adlustrnent By v ‘Suspension ~ check 25 v I ‘Thott cable/ol pump ~ check end 26 ¥ | Yariator and! clutch ~ cheok 2B | ve Wheels and tyres - general check 29 ¥ | * The brake fiuid must be changed every 2 years and the brake hose renewed every 3 years, resective of mileage. | + The coolant must be changed every 3 years, respective of mileage.i2 Model specifications and service schedules Gilera Runner VX125 and VXR1 80/200 ication 1124.2 co, 181.7 be, 197.7 ce single oyindee Tiquld-cooted four-stroke ‘Trensmission ---ariable speed automate, bet driven Ignition Electronic Suspension: Conventional telescopic forks Swingarm 2rd adhustaste twin shook Single aise front and rea) Engine no. prefix: x25 Meni wxnte0 Mea2M vxP20 “M200 104 Frame ne. prefix ZA Meso Wheelbase: 2360 Overall length £91800 ra Overall width 759 mn Seat height BIS mm 132ka s20 tes 0 imies ‘et28 and VAIO 2001 ‘VxR200 2008 Servicing specifications and lubricants ‘Spark plug type SNGK OR 8&8 Spark plug electrode oap 07 1008 mm Idle spood 1600 10 1700 rpm Valve elaaranens (COLD engi Intake 201mm Eehaust : O1smm Front tyre size 420/70-"2 Fear tyre size. $90170-12 Front tyro pressure 20 psi (1.4 Ban) Rear tyre pressure: Rider only... 25 psi(1.6 Bay) Ridor and passenger... 28 psi (1.8 Bay) Fueltype... \Unleaeed peiol(gasotine) min 98 octane ‘Engine oil type [SAE 61N40 API Su syntnetic ol Engine oil quantity ss BPBFOR.T hte Coolant type ..507 disilied water and 50%6 ethylene glyco! antifreeze Cooling system < approx, 0.9 titres Gearbox oil type ‘saW0 API GLS gear oll Gearbox oil quantity approx. 150.cc Brako fuid OTs Air fit of! 5034 petrol (gasoline) Brake tovere . -Gelcium soup grease (NLGI 1-2) Control cables Motor of at cable lubricantModel specifications and service schedules 1:3 Service intervals - Gilera Runner VX125 and VXR180/200 Note: Aivays perform the aly (or0-rid) checks before every service Interval see the beginning of this Manual ‘Tox aectonin | Every 6000%m | very 12.0008 | Every 18,000 kn this Chapter 13750 mies), {Tao mea) | (47,250 mies) or 12 months or2 years or3 years Airfiter~ clean [4 ve Batiery~ check 2 ¥ Brake system ~ check a v L - Baked change - | os To- ee | Brake hose ~ renew 6 { cil 20k lovers —hlretion 7 ¥ _ Sok podsvehoes wear neck [os v Cooking ystom - check 2 v Cooling system ~araning, fushing ard ring 10 o Drive bat ~ check 0 v Drive bot renew uM v Engine ol and tte change 12 ¥ Eusiayatom=cleanaeceleratorpurn mechovon| 1a | - Gearbox o evel = check “ | _ - {Gearbox o ~enange 16 | 24,000 ko Heat aim check and astmant 16 | | vo lle spped — eheck anc astment " —_ Nuts and bots = tighinaes check 8 ve ‘Spark plug ~ gap eneck and agjusiment pa | | Spark plug ~ renew 2 2 Steering heaci bearings ~ehwck and alum: 24 v Suspension ~ check - a _ ¥ - Throttle cat — | | 5 Val cleerances ~ cheok and adustront 27 Frat check YVarlator neck 28 ¥ i _ ‘Wheels and tyes — genera’ chock 20 ¥ _ "The brake fluid musi be changed every 2 yoars ands brake hose renowed every 3 years, wesr-sctve of reage. |» The coolant must be chanasd every 2 years, irespective of mileage "The valve clearances must be checked ater the ist 8000 kin (2750 miles), then at 24.009 kn (15,000 ris) nzervas.iia Model specifications and service schedules Gilera DNA 50 GP eXperience Model identification Engine 49.2 0c single cylinder iquid-cooted two-stroke ‘Transmission arate speed automat ot ven geition Electronic ‘Suspension: From cesses 9 Telescopic forks Rear ‘Swingarm andi eranashock Brake Ssingle cise (ront and reay Engine no. prefix =. 271M Frame no. prefix ‘ZAP C2700 Wheetbaso 4930 msn Ovarall length 1040 men Overall width £700 ren Seat height 770 mmm. Weight (ary) Taka, Fuel tank capacity: Total 9.0 tes Reserve : 1.2 ives Infeooueed 102.2 ce 2000 Servicing specifications and lubricants Spark plug type {Champion RNZC Spark nus electrode geo “0.8 t0 0.7 mm lao ensed 11700 t0 1500 rpm -120/70-14 Serato protect, If te Yyarometer incatae ¢ weak mir, da, Husband tha syste oe Secon (0) 'Stan te ongine end lett reach norma Spent temporatre, hen isk for oak BF th coolant lei consistent low, wed To exéance of ake can be found, havo tne Cave sysam pressive checked by ¢ lem ea & 40 Coolant change — liquid-cooled engine Waring: Alow tho engine te eae! A complotely belore performing thie tmanenance operation. Abe, eon" tio soonest cone It conta! wt Jose herbs pli of plasoe sites oF te scooter: Finse off pas modal, ttn plenty of water antreeze Is highly tonto mgoated. Never leeve entirooce Hog wotie in deoees areaner or utes on tne Noor chien and pots are tracted by le aweot sve and may ck ft chook with focal ethorides (este) about tloposing ef snttresss. Mary Canmuniies have colecion contes which Wel oe et an veaso'n deposed foal ‘ntiroace is also compuribie, so: dont Sore trar open farses Draining 4 Cover the covlant reservoir 2ap with a heavy cloth and release it slowly (see illustration). you hear & hissing sound as you unscrew it (indicating there is stil Dressura in the system), weit until it stops. 2 Position a suitable Container eneath tha ‘sngine on the right-hand side at the ieont,Routine maintenance and servicing procedures 1-21 Pia 10.28 Loosen the clip (avowed) and detach the coolant hese Either loosen the olip securing the coolant hose to the pipe on the side of the engine, ‘nen detach the hose, or loosen the cip onthe Tower hose o7 the watar pump and detach the hose (see llustratione), Allow the coolant to ‘completely drain from the system. Flushing 3 Flush the system with clean tap water by inserting a gardan hose in the reservoir filler rack. Allow wator to run through the system Unt itis clear and flows cleanly out of the detaches hese. If there is a large amount of rust or sediment in the water, remove the raciator and flush out separately (eee Chapter 3) 4 Fiecennest the coolant hose to the pipe or water pump and secure it with its clip (see Step 2) 4 Fil the cooling system via the reservor flr with clear water mixed with a flushing compound. Wake sure the thushing compound 's compatiole with aluminium components, ne fellow the manufacturer's instructions ‘caretuly. Fit the rasonvor cap, 8 Start the engine and allow it to reach norma’ operating temperature, Let it run for ‘about five minutes 7 Stop tho angine. Lott 0 fora while, then remove the reservoir cap, 8 Drain the system once again 8 Fill the system with clean water and repeat the procedure in Steps 6 to 8. Refilling - four-stroke engined models 10 Attach the cpclant Rose to the water ump and secure itwith its op ‘14 Fill the system ail tne way up to the MAX level mark In the reservoir file neck with the proper coolant mixture (see this Chapter’s Speciications). Install te reservoir cap, Note: Pour the coolant into the reservoir slowly to ‘minimise the amount of air entering the system, 12 Star the engine and allow It to ide for 210 3 minutes. Flick the throltie twistgrip part ‘open S or 4 times, so that the engine speed rises, than stop the engine, Warning: Make sure that the scooter is on its centre stand and that the rear wheel is off the 10.2b Detach the lower coolant hose on ‘extemally mounted water pumps ground before starting the engins. if necessary. place 4 support under the ‘engine 0 prevent the rear wheel contacting the ground. 19 Lot the engine cool then remove the reservoir cap. Check that the coolant level is stil up 10 MAX level mark. Top-up the Feservoir if necessary, then reft the cap, 14 Check the system for iaaks, Note: Do not dispose of the old cootant by pouring it down the drain. nstoad pour it into 13 heavy plastic container, cap it tightly anc take it nto av authorised disposal site or ‘garage ~ see Warning at the beginning of this Section, Refilling ~ two-stroke engined models 415 Attach the coolant hose to the pipe and secure it with its ci. 18 Remove the engine cover (see Chanter 8}. Fully loosen the bleed screw and attach one fend of a suitable length ot rubber tube to it {Gee llustration), Place the other eng iio the coolant reservoir, 117 Fl the system al the way up to the MAX level line on the reservoir with the proper coojant mixture (see this Chapter’s Specifications). Note: Pour the cooieat into the reservoir slowty te minimise the areount of air entorng the system. AS you fill the reservoir, ai wil! bubble up fom the rubber tube atachod to the Bleed screw. 418 When the system is full and 90 more alts coming out of the tube, tighten the bleed Sorew and install the reservoir cap. 49 Start the engine and allow it to ila for 2 to 3 minutes. Flick the thrattie twistgrip part ‘open 3 or 4 times, $0 that the engine speed rises, then stop the engine. Looser the biesd ‘screw to allow any air trapped in the system to come out, then tighten the screw. Warning: Make sure that the scooter is on its centra etand and that the rear wheel 18 off the ground oefore starting the engine. if necessary, place # support under the ‘engine to provent the rear wheel contacting the ground 20 Let the engine cool then remove the Feservoir cap. Check that the coalan! level is 40.16 Cooling eystom bleed seraw stil up to MAX leval line. Top-up the reservoir i necessary, then refit the cap, 21, Check the system for sans. Note: Do not alspose of the old coolant by pouring it down the draio. Instead pour H into @ ‘heavy plastic container, capi ght and taka it inle an authorised disposal site ar garage ~ see Warning atthe beginning of this Section. 11 Drive belt inspection x and renewal & 1 Referring to Chapter 20, remowe the dive bolt cover, then inspect tne bolt as gescribed land renew it if necessary. In the event of Premature bel: won, the cauge shoutd be Investigated. Note: The drive belt must be renewed at the speciied servico itera 12 Engine oil and filter change ~ Sy four-stroke engine x Werning: 8 careful when ‘draining the oll, a8 the exhaust pipe, the engin, and the oil itsel! ean cause severe bums. 1 Olt and fiter changes are the single most Important maintenance procedure you can perform on a four-stroke engine. The of not Only {Ubricates the intsnal pans of the angina, but it also acts as a coolant, a cleane’, & sealant. and a protector, decause of these demands, Ure o' takes a terrilc amount of abuse and should be roplaced at the specified service interval with new all at the recommended grade and ype. Saving ¢ ie money on the difference in cost betwesn = (9000 oll and a cheap oil won't pay off the engine is damaged. 2 Before changing the of, warm up the engine 80 the ol will drain easily. Stop the engine and turn the igrition OFF. Par the scooter an ils centre siand, and position ‘lean drain tray below the engire 8 Unscrew the of filer plug from the tot-raet side of the engine to vent the crankease and to act as a reminder thet Mere Is 0 cin the engine (see iliusiration),