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SERVICE STATION MANUAL
677205
Typhoon 125 4T (2010-)

SERVICE STATION
MANUAL
Typhoon 125 4T (2010-)
The descriptions and images in this publication are given for illustrative purposes only. While the basic
features as described and illustrated in this manual remain unchanged, Piaggio & C. S.p.A. 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 deems necessary to improve the product, or which
are required for manufacturing or commercial reasons.
Not all the versions shown in this publication are available in every country. Availability of the individual
versions must be verified with the official PIAGGIO sales network.
© Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
Typhoon 125 4T (2010-)
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles
has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant
changes to vehicle characteristics or to specific repair operations will be communicated by updates to
this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools
are unavailable. It is therefore advisable to read the sections of this manual concerning special tools,
along with the special tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment 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
PRE-DELIVERY PRE DE
TECHNICAL DATA DT
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
CHASSIS CHAS
TIME TIME
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Typhoon 125 4T (2010-) Pre-delivery
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection

Locking check
- Safety fasteners
- Fixing screws
Safety fasteners:
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Swinging arm - frame pin
Engine - swinging arm pin
Engine arm pin - Chassis arm
Handlebar lock nut
Lower steering ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights, parking lights and their warning lights
- Headlight adjustment according to regulations in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel gauge
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 7
Pre-delivery Typhoon 125 4T (2010-)
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATELY CHARGING THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS
USED FOR THE FIRST TIME WITH SHORTEN THE LIFE OF THE BATTERY.
WARNING
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO-
TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. 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 oil level
Road test
Test ride:
- Cold start
- Instrument operations
- Response to throttle control
- Stability on acceleration and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
Static test
Static control after the test drive:
- Warm start
- Starter operation
PRE DE - 8
Typhoon 125 4T (2010-) Pre-delivery
- Minimum holding (turning the handlebar)

- Uniform turning of the steering
- Possible leaks
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY
BURST.
Functional inspection
Functional Checks:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Check throttle control travel
Others
- Check documentation
- Check the chassis and engine numbers
- Tool kit
- Licence plate fitting
- Locks checking
- Tyre pressure check
- Fitting of mirrors and possible accessories
PRE DE - 9
INDEX OF TOPICS
TECHNICAL DATA DT
Typhoon 125 4T (2010-) Technical Data
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air carefully to avoid
the risk of inhaling dust produced by worn 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 spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, seal rings and cotter pins when reassembling.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
DT - 11
Technical Data Typhoon 125 4T (2010-)
Vehicle identification
Chassis prefix LBMM701
Engine prefix M701M
Engine Data
ENGINE
Specification Desc./Quantity
Engine Single cylinder 4-stroke
Timing system Single overhead camshaft (SOHC) with 2 valves
Valve clearance intake 0.10
exhaust 0.15
Bore x stroke 57 x 48.6 mm
Engine capacity 124 cm³
Compression ratio (10.6+/-0.5):1
carburettor KEIHIN CVEK26
Engine idle speed approx. 1,600 - 1,800 rpm
Starting Electric
Max power to the shaft 10.5 CV at 8000 rpm
Liquid Forced-circulation air cooling.
Dimensions and mass
DT - 12
WEIGHTS AND DIMENSIONS

Maximum length 1947
Overall width 730
Max. height to the windshield 1130 mm
Wheelbase 1355
Kerb weight 117 kg
Transmission
TRANSMISSION
Transmission With continuously variable expandable pulley transmission
with torque server, V belt, automatic clutch, gear reduction unit
and transmission housing with forced air circulation cooling.
Capacities
CAPACITY
Engine oil 1.10 l
Rear hub oil approx. 250 cc
Fuel tank capacity ~ 7.0 litres (2.0 l of which is reserve)
Fork stem (oil level height without spring, compressed fork) 85 mm
Electrical system
ELECTRICAL SYSTEM
Starting Electric
Spark plug Champion NGK CR7EB - RG6YC
Ignition advance 15° ± 1° at 2,000 rpm
Battery 12 V / 10 Ah
Fuses No. 1 20A, No. 1 15A, No. 1 7.5A
Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-
vance, with separate HV coil.
Alternator alternating current
Frame and suspensions
CHASSIS AND SUSPENSION

Frame Tubular steel frame
Front suspension Ø 35 Hydraulic telescopic fork - travel: 90 mm
Rear suspension Hydraulic single shock absorber and spring adjustable to 4 po-
sitions at preloading; travel: 80 mm.
DT - 13
Brakes
BRAKES
Front brake Ø 220 mm hydraulically operated disc brake with floating cal-
liper, controlled from lever on RH end of handlebar.
Rear brake Ø 110 mm drum brake
Wheels and tyres
WHEELS AND TYRES

Front wheel rim Die-cast aluminium alloy; 3.50 x 10"
Front tyre Tubeless 120/80 -10"
Rear wheel rim Die-cast aluminium alloy: 3.50"x10"
Rear tyre Tubeless 120/80 - 10"
Front tyre pressure 1.5 bar
Rear tyre pressure 1.8 bar
Rear wheel pressure (rider and passenger): 2.0 bar
Secondary air
In order to reduce polluting emissions, the vehicle

is furnished with a catalytic converter in the muf-
fler.
To favour the catalytic process, an extra amount
of oxygen is added via a secondary air system
(SAS).
This system allows more oxygen to be added to
the unburned gases before they reach the con-
verter, thus improving the action of the catalytic
converter.
The air enters the exhaust duct from the head, and
is purified by a black filter.
The system is fitted with a control valve that disa-
bles operation while decelerating to avoid unwan-
ted noise.
To ensure the best functioning of the SAS system,
every 12,000 km the scooter should be taken to an
Authorised Piaggio Service Centre to have the
filter cleaned (Scheduled maintenance operations
section).
DT - 14
The filter sponge should be cleaned with water and

mild soap, then it should be dried with a cloth and
slight blows of compressed air.
CAUTION
CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE

TO CARRY OUT THESE OPERATIONS.
Carburettor
125cc Version
Kehin
CARBURETTOR SETTING
Type CVEK26
Throttle valve diameter Ø 26.5
Diffuser diameter Ø 26.4
Setting stamping 262A
Maximum jet 82
Maximum air jet (on the body) 85
Tapered pin stamping NELA
Throttle valve spring 130 ÷ 180 gr.
Minimum jet 35
Idle air jet (on the body) 150
Idle mixture adjustment screw initial opening 1¾
Starter nozzle 42
Starter air jet (on the body) Ø 1.5
Starter pin travel 10 mm (at 24°)
Starter resistance 20 Ohm (at 24°)
Tightening Torques
HEAD AND CYLINDER

Name Torque in Nm
Ignition spark plug 18 Nm
Head cover screws 11 - 13
Nuts fixing head to cylinder (*) 28 to 30
Head fixing screws (external) 11 to 13
Starter ground screw 7 to 8.5
Flywheel air duct screw 3-4
Pressure reducer counterweight retainer 7 - 8.5
Camshaft pulley screw 12 - 14
Timing chain tensioner slider screw 10 - 14
Starter counterweight support screw 11 to 15
Tensioner screw 5 to 6
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 5-6
Nut fixing silencer to cylinder head 16 - 18
Head intake manifold screw 11 to 13
(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.
DT - 15
TRANSMISSION
Name Torque in Nm
Drive pulley nut (°) 75 - 83
Transmission cover screw 11 to 13
Driven pulley shaft nut 54 to 60
Rear hub cap screws 24 - 27
Clutch unit nut on driven pulley 55 to 60
(°) Apply LOCTITE 243 threadlock
FLYWHEEL
Name Torque in Nm
Flywheel fan screws 3 to 4
Stator assembly screws (°) 3-4
Flywheel nut 52 - 58
Pick-up screw 3 to 4
(°) Apply LOCTITE 243 threadlock
CRANKCASE AND CRANKSHAFT

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4-6
shaft) screws
Oil filter on crankcase fitting 27 - 33
Rear brake cam tightening screw 11 to 13
Engine-crankcase coupling screws 11 to 13
Pre-filter cap 24 to 30
Starter screws 11 to 13
Silencer to crankcase fixing screws 24 to 27
Engine oil drainage cap 24 to 30
Oil sump screws 11 to 13
Oil pump central screw 12 to 14
Oil pump cover screws 0.7 - 0.9
Minimum oil pressure switch 12 - 14
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 30 to 36
Lower steering ring nut 10 - 13 (loosen by 90°)
Handlebar fixing screw 45 to 50
Mirror fastening spacer 25
CHASSIS ASSEMBLY
Name Torque in Nm
Engine arm pin - chassis arm 45.5
Centre stand pivot on engine 42.5
Silent block-swinging arm retaining bolts 42.5
FRONT SUSPENSION
Name Torque in Nm
Piston tightening fork lower screw 25 - 35
Front wheel axle nut 45 - 50
Fork clamp screw 20 to 25
Fork stanchion upper cap 15 ÷ 30
Safety screw on fork leg 6-7
FRONT BRAKE
Name Torque in Nm
Brake fluid hose-pump fitting 20 - 25
Brake fluid pipe-calliper fitting 20 to 25
Calliper to fork tightening screw 20 to 25
Disc tightening screw 8 to 12
Oil bleed screw 8 - 12
DT - 16
Name Torque in Nm
Pump U bolt screw 8
Brake pad fastening screw 15 - 20
REAR SUSPENSION
Name Torque in Nm
Rear wheel axle 115
Shock absorber nut 22.5
FUEL TANK UNIT

Name Torque in Nm
Fuel tank to chassis fixing screw 10
SADDLE UNIT
Name Torque in Nm
Saddle plate fixing nut 10
BODYWORK UNIT
Name Torque in Nm
Helmet compartment fixing screw 3
Rear grab handle fixing screw 20.5
Battery cover fixing screw 6
Front wheel housing to chassis fixing screw 6
Front wheel housing to leg shield back plate fixing screw 3
Front mudguard fixing screw 6
Footrest fixing screw 6
Screw fixing leg shield back plate to chassis 6
Leg shield back plate to leg shield fixing screw 3
Footrest spoiler fixing screw 6
Passenger footrest protection fixing screw 3
Passenger footrest to side body panel fixing screw 6
Rear mudguard fixing screw 6
Rear brake adjustment nut 5
Overhaul data
Assembly clearances
Cylinder - piston assy.

125 version
PISTON TO CAST IRON CYLINDER COUPLING (125)

Name Initials Cylinder Piston Play on fitting
Coupling M 56.997 - 57.004 56.944 - 56.951 0.046 - 0.060
Coupling N 57.004 - 57.011 56.951 - 56.958 0.046 - 0.060
Coupling O 57.011 - 57.018 56.958 - 56.965 0.046 - 0.060
Coupling P 57.018 - 57.025 56.965 - 56.972 0.046 - 0.060
coupling 1st oversize M1 57.197 - 57.204 57.144 - 57.151 0.046 - 0.060
coupling 1st oversize N1 57.204 - 57.211 57.151 - 57.158 0.046 - 0.060
coupling 1st oversize O1 57.211 - 57.218 57.158 - 57.165 0.046 - 0.060
coupling 1st oversize P1 57.218 - 57.225 57.165 - 57.172 0.046 - 0.060
Coupling 2nd oversize M2 57.397 - 57.404 57.344 - 57.351 0.046 - 0.060
Coupling 2nd oversize N2 57.404 - 57.411 57.351 - 57.358 0.046 - 0.060
Coupling 2nd oversize O2 57.411 - 57.418 57.358 - 57.365 0.046 - 0.060
Coupling 2nd oversize P2 57.418 - 57.425 57.365 - 57.372 0.046 - 0.060
Coupling 3rd oversize M3 57.597 - 57.604 57.544 - 57.551 0.046 - 0.060
DT - 17
Name Initials Cylinder Piston Play on fitting

Coupling 3rd oversize N3 57.604 - 57.611 57.551 - 57.558 0.046 - 0.060
Coupling 3rd oversize O3 57.611 - 57.618 57.558 - 57.565 0.046 - 0.060
Coupling 3rd oversize P3 57.618 - 57.625 57.565 - 57.572 0.046 - 0.060
Piston rings
SEALING RINGS (125)

Name Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 - 0.30
Oil scraper ring 57x1 A 0.10 - 0.30
Oil scraper ring 57x2.5 A 0.10 - 0.35
Compression ring 1st 57.2 x 1 A 0.15 - 0.30
oversize
Oil scraper ring 1st 57.2x1 A 0.10 - 0.30
oversize
Oil scraper ring 1st 57.2x2.5 A 0.10 - 0.35
oversize
Compression ring 2nd 57.4x1 A 0.15 - 0.30
oversize
Oil scraper ring 2nd 57.4x1 A 0.10 - 0.30
oversize
Oil scraper ring 2nd 57.4x2.5 A 0.10 - 0.35
oversize
Compression ring 3rd 57.6x1 A 0.15 - 0.30
oversize
Oil scraper ring 3rd 57.6x1 A 0.10 - 0.30
oversize
Oil scraper ring 3rd 57.6x2.5 A 0.10 - 0.35
oversize
Maximum clearance after use: 1 mm
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Transmissionside half- 16.6 +0-0.05 A D = 0.20 - 0.50
shaft
Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod with PP 18 -0.10 -0.15 C 0.20 to 0.50
Crank pin width 51.400 E
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

Crankshaft Category 1 28.998 - 29.004
Crankshaft Category 2 29.004 - 29.010
DT - 18

Crankcase Category 1 32.953 - 32.959
Crankcase Category 2 32.959 - 32.965
Crankshaft half-bearing Category B - blue 1.973 - 1.976
Crankshaft half-bearing Category C - yellow 1.976 - 1.979
Crankshaft half-bearing Category E - green 1.979 - 1.982
Crankshaft category 1 - E-E
Crankcase category 1
Crankshaft category 1 - C-C
Crankshaft category 2 - C-C
Crankshaft category 2 - B-B
Crankshaft/crankcase axial clearance: 0.15 to 0.40
Slot packing system
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool
- Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping
the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.
- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)
- Calculate the difference between the two measurements: use the chart below to identify the thickness
of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness
to keep the correct compression ratio.
- Remove the special tool and the cylinder.
Characteristic
Compression ratio
10.6: 1
DT - 19
SHIMMING SYSTEM
Value measured 0 - 0.1
Thickness 0.8 ± 0.05
Value measured 0.1 - 0.3
Value measured 0.3 - 0.4
DT - 20
INDEX OF TOPICS
TOOLING TOOL
Tooling Typhoon 125 4T (2010-)
SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y009 Bell for OD 42-mm bearings
001467Y013 Calliper to extract ø 15-mm bearings
002465Y Calliper for circlips
005095Y Engine support
006029Y Punch for fitting steering bearing on the

steering tube
TOOL - 22
Typhoon 125 4T (2010-) Tooling

008564Y Flywheel extractor
020004Y Punch for removing steering bearings

from headstock
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crankshaft

alignment
020150Y Air heater mounting
020151Y Air heater
020193Y Oil pressure gauge
TOOL - 23

020201Y Spacer bushing driving tube
020262Y Crankcase splitting plate
020263Y Driven pulley assembly sheath
020271Y Tool for removing-fitting silent bloc
020306Y Punch valve seal rings fitting
020329Y Mity-Vac vacuum pump
020330Y Stroboscopic light to check timing
TOOL - 24

020331Y Digital multimeter
020332Y Digital rpm indicator
020334Y Multiple battery charger
020335Y Magnetic mounting for dial gauge
020357Y 32 x 35-mm Adaptor
TOOL - 25

020359Y 42 x 47 mm Adaptor
020360S 52 x 55 mm adaptor
020363Y 20-mm guide
020364Y 25-mm guide
020368Y driving pulley lock wrench
020375Y 28 x 30 mm adaptor
TOOL - 26

020376Y Adaptor handle
020382Y Valve cotters equipped with part 012 re-

moval tool
020382Y011 adapter for valve removal tool
020412Y 15-mm guide
020423Y Driven pulley lock wrench
020424Y Driven pulley roller casing fitting punch
TOOL - 27

020425Y Punch for flywheel-side oil seal
020426Y Piston fitting fork
020427Y Piston assembly band
020428Y Piston position check mounting
020430Y Tool for fitting the pin snap rings
020431Y Valve oil seal extractor
TOOL - 28

020434Y Union for oil pressure measurement
020439Y 17-mm guide
020444Y Tool for installing/removing clutch on/

from driven pulley
020456Y Ø 24 mm adaptor
020565Y Flywheel lock calliper spanner
020622Y Transmission-side oil seal punch
TOOL - 29
INDEX OF TOPICS
MAINTENANCE MAIN
Typhoon 125 4T (2010-) Maintenance
Maintenance chart
MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
Clean the SAS air filter every 2 years
* Check level every 3,000 km
** Replace every 2 years
Km x 1,000 1 6 12 18 24 30 36 42 48 54 60
Safety fasteners I I I I I I
Spark plug I R I R I R I R I R
Centre stand L L L L L L L L L L
Drive belt I R I R I R I R I R
Throttle control A A A A A A
Air filter C C C C C C C C C C
SAS filter C C C C C
Oil filter R R R R R R R R R R
Oil mesh filter C C C C C C C C C C C
Valve clearance A A A A
Electrical system and battery I I I I I I I I I I I
Cylinder cooling system C C
Brake levers L L L L L L
Brake fluid ** I I I I I I I I I I I
Engine oil * R R R R R R R R R R R
Hub oil R I I I R I R I R I I
Headlight aiming adjustment A A A A A
Brake pads I I I I I I I I I I I
Sliding shoes / CVT rollers I R I R I R I R I R
Tyre pressure and wear I I I I I I I I I I I
Vehicle road test I I I I I I I I I I I
Idle speed A A A A A A
Odometer gear L L L L L
Suspension I I I I I
Steering A A A A A A
Transmission L L L L L
Operation time 80' 150' 160' 150' 175' 95' 270' 95' 175' 150' 160'
Recommended products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
Transmission oil 80W-90 Lubricant for gearboxes and transmis- SAE 80W-90; API GL-4
sions.
Engine oil 5W -40 Synthetic-based lubricant for four-stroke SAE 5W-40; JASO MA, MA2; API SL;
engines. ACEA A3
Oil for filter sponges Special product for impregnating sponge -
filtering elements.
Engine oil 5W -40 Synthetic-based lubricant for four-stroke SAE 5W-40; JASO MA, MA2; API SL;
engines. ACEA A3
Lithium-based grease Lithium-based grease, suitable for vari- Yellow grease ISO L-X-BCHA 3 - DIN 51
ous uses. 825 K3K -20
DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CU-
NA NC 956 DOT4
Calcium based grease Calcium grease Smooth-textured appearance; Ivory col-
oured Specification TL 9150 066, symbol
NATO G 460
Water repellent spray grease Water repellent pouring calcium spray R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -
grease. I.A.T.A. 2 - I.M.D.G. class 2 UN 1950
Page 9022 EM 25-89
Fork oil 7.5W Fork oil. SAE 7.5W
MAIN - 31
Maintenance Typhoon 125 4T (2010-)
Checking the spark advance
- To check ignition advance, use the stroboscopic light with induction pincers connected to the spark
plug power wire.
- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the
pincers must be pointing at the spark plug).
- Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines).
- Start the engine and check that the light works properly and the rpm indicator can read also the high
rpm (e.g. 8000 rpm).
- If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive
load on the spark plug power line (10 - 15 KΩ in series to HV wire).
- Operating on the flash bulb phase difference cal-

ibrator, make the reference on the flywheel cover
coincide with the fan reference as shown in the
photograph. Read the advance degrees indicated
by the stroboscopic light and compare them with
those specified.
Characteristic
Ignition advance check
15° ± 1° at 2000 rpm - 28° ± 1° at 6000 rpm
MAIN - 32
Spark advance variation
ADVANCE VARIATION
Operation threshold First threshold: 9000±50
Second threshold: 9300±50
Reactivation threshold First threshold: 8900±50
Second threshold: 9200±50
Spark elimination First threshold: 1 spark on 7
Second threshold: 2 sparks on 3
Spark plug
Place the vehicle on its central stand

- Remove the central cover;
- Detach the coil from the chassis, leaving it con-
nected to the system, and disconnect the spark
plug H.V. cable cap
- Unscrew the spark plug using the socket wrench
supplied.
-Examine the condition of the spark plug, check
that the insulating material is whole and measure
MAIN - 33
the distance between the electrodes using a feeler

gauge.
-Adjust the distance if necessary by bending the
side electrode very carefully.
In the case of defects, replace the spark plug with
one of the specified type.
- Engage the spark plug with the due inclination
and screw it right down by hand, then do it up with
the wrench at the prescribed torque.
- Fit the cap on the spark plug as far as it will go.
- Refit the coil and the central cover.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-
GINE IS COLD. THE SPARK PLUG MUST BE REPLACED
EVERY 5,000 KM. USING NON-COMPLYING IGNITION
CONTROL UNITS OR SPARK PLUGS OTHER THAN
THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE EN-
GINE.
Electric characteristic
Recommended spark plug
NGK CR7EB
Alternative spark plug
CHAMPION RG6YC
Electrode gap
0.6 to 0.7 mm.
Locking torques (N*m)

See also
Chassis
Hub oil
MAIN - 34
Check
Do the following to check the correct level:

- Ride a few kilometres until the regular working
temperature is reached, then stop the engine.
- Park the vehicle on level ground and rest it on the
centre stand.
- Unscrew the oil filler dipstick, dry it with a clean
cloth and reinsert it.
- Remove the dipstick and make sure that the oil
level reaches the indicated reference notch.
- Screw up the oil dipstick back in and make sure
it is locked properly in place.
Transmission oil 80W-90 Lubricant for gear-
boxes and transmissions.
SAE 80W-90; API GL-4
Replacement
- Ride a few kilometres until the regular working

temperature is reached, then stop the engine.
- Park the vehicle on level ground and rest it on the
centre stand.
- Remove the oil filler dipstick and drain out the oil
completely.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.
- Check the level.
- Screw the oil filler dipstick back into place, being
sure it is completely blocked.
Characteristic
Rear hub oil
Quantity: ~ 250 cc
MAIN - 35
Air filter
- Remove the cap of the air cleaner, unscrewing

the five screws and the fixing knob.
- Take out the filtering element.
Cleaning:
- Wash with water and neutral soap.
-Dry with a clean cloth and short blasts of com-
pressed air.
-Saturate with a 50% mixture of gasoline and oil.
- Drip dry the filtering element and then squeeze it
with your hands without wringing.
-Let it dry and refit it again.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER.
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
Oil for filter sponges Special product for im-
pregnating sponge filtering elements.
-
FILTER BOX REMOVAL

- Undo the two screws indicated.
- Loosen the indicated clamps and slide off the fil-

ter box.
MAIN - 36
Engine oil
Replacement
Change oil as indicated in the scheduled mainte-

nance table. The engine must be emptied by drain-
ing off the oil through the drainage plug of the
mesh pre-filter, flywheel side; furthermore to facil-
itate oil drainage, loosen the cap/dipstick. Once all
the oil has drained through the drainage hole, un-
screw the oil cartridge filter and remove it.
Since a certain quantity of oil still remains in the
circuit, fill adding approx. 600 - 650 cm³ of oil
through the cap. Then start up the vehicle, leave it
running for a few minutes and switch it off: After
about five minutes, check the level and, if neces-
sary, top-up but never exceeding the MAX level
reference mark.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
Engine oil 5W -40 Synthetic-based lubricant for
four-stroke engines.
SAE 5W-40; JASO MA, MA2; API SL; ACEA A3

Engine oil drainage cap 24 to 30
See also
Engine
oil filter
Check
In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and
the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all
four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be
considered normal, especially if during the run-in period. Consumption can particularly reflect the con-
ditions of use (i.e. when driving at 'full acceleration' all the time, oil consumption increases).
MAIN - 37
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) Undo cap/dipstick, dry it off with a clean cloth
and reinsert it, screwing down completely.
3) Remove the cap/dipstick again and check that
the level is between the max. and min levels; top-
up, if required.
The MAX level reference mark indicates the
amount of oil in the engine. If the check is carried
out after the vehicle has been used, and therefore
with a hot engine, the level will be lower; in order
to carry out a correct check, wait at least 10 mi-
nutes after the engine has been stopped so as to
get the correct level.
Characteristic
Engine oil
1.10 l
The oil should be topped up after having checked the level and in any case by adding oil without ever
exceeding the MAX. level.
Restoring the level between the MIN and MAX reference marks requires ~ 400 cm³ of oil.
Engine oil filter
Change oil and replace filter as indicated in the scheduled maintenance table. Use new oil of the rec-
ommended type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
Oil pressure warning light
The vehicle is equipped with a tell-tale light on the dashboard that lights up when the key is turned to
the «ON» position. However, this light should switch off once the engine has been started.
If the light turns on during braking, at idling speed or while turning a corner, it is necessary to
check the oil level and the lubrication system.
MAIN - 38
transmissions
Put the vehicle in gear and regulate the idling by

turning the adjustment screw on the left-hand side
of the carburettor.
Adjust the control cables as follows.
Handlebar control:
- remove the front handlebar cover leaving it con-
nected to the system;
- remove the rubber hoods and regulate the cable
adjustments in such a way that they cause a min-
imum clearance on the throttle.
Carburettor control:
- remove the inspection cover of the helmet com-
partment;
- remove the rubber hoods and regulate the cable
adjustments in such a way that the sheaths have
a minimum clearance.
MAIN - 39
Checking the ignition timing
-Remove the flywheel fan.

-Rotate the flywheel until the reference (arrow)
matches the crankcase operation end as shown in
the figure (TDC). Make sure that the 2V reference
point on the camshaft control pulley is aligned with
the reference point on the head as shown in the
second figure. If the reference mark is opposite the
indicator on the head, make the crankshaft turn
once more.
-The TDC reference mark is repeated also be-
tween the flywheel cooling fan and the flywheel
cover.
To use this reference mark, remove the spark plug
and turn the engine in the opposite direction to the
normal direction of rotation using a compass span-
ner applied to the camshaft drive sprocket hous-
ing.
N.B.
TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.
Checking the valve clearance
-To check valve clearance, centre the reference marks of the timing system
- Use a feeler gauge to check that the clearance between the valve and the register corresponds with
the indicated values. When the valve clearance values, intake and exhaust respectively, are different
from the ones indicated below, adjust them by loosening the lock nut and operate on the set screw with
a screwdriver.
Intake: 0.10 mm (when cold)
Exhauste: 0.15 mm (when cold)
Braking system
MAIN - 40
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the han-
dlebars perfectly horizontal;
- Check the fluid level through the corresponding
sight glass.
A certain lowering of the level is caused by wear
on the brake pads.
Top-up
Proceed as follows:
- Undo the two screws and remove the cover with
the seal.
- Top-up using only the fluid specified, without ex-
ceeding the maximum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN,

AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT,
RINSE WITH WATER.
CAUTION
BRAKE CIRCUIT FLUID IS HIGHLY CORROSIVE: DO NOT
LET IT COME INTO CONTACT WITH PAINTED PARTS.
CAUTION
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS
MOISTURE FROM THE SURROUNDING AIR. IF THE CON-
TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A
CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
NEVER USE BRAKE LIQUID FROM OPEN OR PARTIALLY
USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, FLUID
SHOULD BE REPLACED EVERY 20,000 KM OR EVERY 2
YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
DOT 4 brake fluid Synthetic brake fluid.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC
956 DOT4
MAIN - 41
Headlight adjustment
Proceed as follows:
1. Position the vehicle in running order and with
the tyres inflated to the prescribed pressure, onto
a flat surface 10 m away from a half-lit white
screen; ensure that the longitudinal axis of the ve-
hicle is perpendicular to the screen;
2. Turn on the headlight and check that the boun-
dary of the light beam projected onto the screen is
not higher than 9/10 or lower than 7/10 of the dis-
tance between the centre of the headlight and the
ground;
3. Otherwise, adjust the headlight by turning the
knobs of the body inside the wheel housing.
- Tighten the screw (clockwise) to raise the light
beam;
- undo the screw (anticlockwise) to lower the light
beam.
N.B.
THE PROCEDURE DESCRIBED IS THAT ESTABLISHED
BY EUROPEAN STANDARDS FOR THE MAXIMUM AND
MINIMUM HEIGHT OF THE LIGHT BEAM. REFER TO THE
STATUTORY REGULATIONS IN FORCE IN EVERY COUN-
TRY WHERE THE VEHICLE IS USED.
CO check
- Remove the inspection cover of the SAS valve,

by undoing the three indicated screws.
- Remove the clamp and the secondary air valve
as shown in the photograph.
- Connect the exhaust fumes outlet tube with the
secondary air tube rubber sleeve. This connection
should guarantee the system tightness to avoid
distorting the CO value reading
N.B.
IN CASE OF 1000 PPM UNBURNED HYDROCARBONS
(HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYS-
TEM, THE VALVE CLEARANCE AND THE EXHAUST
VALVE TIGHTNESS.
N.B.
MAIN - 42
IN CASE OF UNSTABLE CO, CHECK THAT THE CARBU-

RETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYS-
TEM AND THE DEPRESSION SEALS WORK ADEQUATE-
LY
N.B.
OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN
THE TANK AND THE FUEL CIRCUIT.
N.B.
ALSO CHECK THE CARBURETION ADJUSTMENT IS OB-
TAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND
4 TURNS.
N.B.
CHECK THAT THE RESULT IS OBTAINED WITH THE
VALVE GAS IN CLOSED POSITION.
Specific tooling
020332Y Digital rpm indicator
Characteristic
CO Check
3.8±0.7 to 1650±50 RPM
SAS filters inspection and cleaning
- Remove the screw fixing the SAS valve to the

flywheel cover, indicated in the photograph.
- Remove the 4 flywheel cover screws indicated in

the photograph and remove the flywheel cover.
MAIN - 43
- Remove the filter indicated in the photograph.

- Check the condition of the fan cover gasket and
its correct positioning.
- Check the SAS filter housing for dents or defor-
mations
- Clean the SAS filter carefully. Replace the filter if
it is damaged or deformed.
To refit, carry out the removal operations but in re-
verse order.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER
MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE
SCHEDULED MAINTENANCE TABLE.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY
AIR FILTER
MAIN - 44
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Troubleshooting Typhoon 125 4T (2010-)
Engine
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (AGIP
Filter Oil), then hand dry without squeezing, allow to drip dry
and then reassemble.
Fuel nozzles or cock clogged or dirty Dismantle, wash with solvent and dry with compressed air
Dirty or faulty vacuum-operated cock Check the filter on the cock, remove the petrol and wash the
tank, if necessary. Replace the cock as a last resource.
Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace
if necessary.
Excessive drive belt wear Check it and replace, if necessary
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Engine oil level exceeds maximum Check for causes and fill to reach the correct level
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Silencer obstructed Replace
Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-
aged parts and lubricate the driven pulley moveable guide with
Montblanc Molybdenum Grease
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Valve seat distorted Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or just the piston rings
Rear wheel spins at idle
REAR WHEEL ROTATES WITH ENGINE AT IDLE

Idling rpm too high Adjust the engine idle speed and the CO%, if necessary.
Clutch fault Check the springs / clutch masses
Starting difficulties
START-UP PROBLEMS
Flat battery Check the state of the battery. If it shows signs of sulphating
replace it and bring the new battery into service charging it for
eight hours at a current of 1/10 of the capacity of the battery
itself
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
Flooded engine 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 engine 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.
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
Rpm too low at start-up or engine and start-up system dam- Check starter motor
aged
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-
plying a vacuum to the vacuum pipe
TROUBL - 46
Typhoon 125 4T (2010-) Troubleshooting

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace
if necessary.
Start-up enabling buttons failure Check continuity using an Ohm meter, with the switch pressed;
replace if necessary
Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air
Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (AGIP
Filter Oil), then hand dry without squeezing, allow to drip dry
and then reassemble.
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKY EXHAUST

Worn valve guides Check and replace the head unit if required
Worn valve oil seal Replace the valve oil seal
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level by adding the recommended oil type.
Engine tends to cut-off at full throttle
THE ENGINE TENDS TO STOP AT MAXIMUM THROTTLE

Maximum jet clogged Remove the carburettor, wash with solvent and dry with com-
pressed air
Water or condensation in the carburettor chamber Remove the tank, wash with solvent and dry with compressed
air
Level in chamber too low Restore the level in the chamber by bending on the float the
thrusting reed of the petrol intake rod so as to have the float
parallel to the chamber level with the carburettor inverted.
Engine tends to cut-off at idle
THE ENGINE TENDS TO STOP AT IDLE SPEED

Incorrect idle adjustment Adjust using the rpm indicator
Incorrect timing Time the system and check the timing system components
The starter remains on Check: electric wiring, circuit not interrupted, mechanical
movement and power supply; replace if necessary
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
Pressure too low at the end of compression Check the thermal group seals and replace worn components
Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
TROUBL - 47
High fuel consumption
EXCESSIVE FUEL CONSUMPTION

Air filter blocked or dirty Clean according to the procedure
Inefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Loose nozzles Check the maximum and minimum nozzles are adequately
fixed in their fittings
Incorrect float level Restore the level in the chamber by bending on the float the
thrusting reed of the petrol intake rod so as to have the float
parallel to the chamber level with the carburettor inverted.
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Slippage or irregular functioning Check that there is no grease on the masses.
Check that the faying surface between the clutch masses and
the clutch housing is mainly in the middle and with equivalent
specifications on the three masses.
Check that the clutch housing is not scored or worn abnormally
Never run the engine without the clutch housing
Insufficient braking
INEFFICIENT OR NOISY BRAKING

Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or
drum wear conditions.
Front brake disk loose or deformed 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.
Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Excessive clearance in the rear brake control cable Adjust the clearance with the appropriate adjuster located on
the back part of the crankcase.
Brakes overheating
BRAKES OVERHEATING
Rubber gaskets swollen or stuck. Replace gaskets.
Compensation holes on the pump clogged. Clean carefully and blast with compressed air.
Brake disc slack or distorted 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.
Defective piston sliding. Check calliper and replace any damaged part.
TROUBL - 48
Typhoon 125 4T (2010-) Troubleshooting
Electrical system
Battery
BATTERY
Battery The battery is the electrical device in the system that requires
the most frequent inspections and thorough maintenance. 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 5 - 6 months. If the battery is fitted
on a motorcycle, be careful not to invert the connections, keep-
ing in mind that the black ground wire is connected to the
negative terminal while the red wire is connected to the terminal
marked+. Follow the instructions in the ELECTRICAL SYSTEM
chapter for the recharging of the batteries.
Turn signal lights malfunction
TURN INDICATORS NOT WORKING

Electronic ignition device failure With the ignition switch set to "ON" jump the contacts 1 (Blue-
Black) and 5 (Orange) on the control unit connector.
If by operating the turn indicators control the lights are not
steadily on, replace the control unit; otherwise, check the cable
harness and the switch.
Steering and suspensions
Heavy steering
STEERING HARDENING
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Excessive steering play
EXCESSIVE STEERING CLEARANCE

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continue
in turning the steering even after making the above adjust-
ments, check the seats in which the ball bearings rotate: re-
place if they are recessed.
TROUBL - 49
Noisy suspension
NOISY SUSPENSION
Noisy suspension If the front suspension is noisy, check: that the front shock ab-
sorber works properly and the ball bearings are good condition.
Finally, check the locking torque of the wheel axle nut, the
brake calliper and the disc. Check that the swinging arm con-
necting the engine to the frame and the rear shock absorber
work properly.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Oil leakage from suspension Replace the rear shock absorber or the front fork cartridge.
TROUBL - 50
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system Typhoon 125 4T (2010-)
Key:
1. Multiple connectors
2. Horn
3. Horn button
4. Fuel level transmitter
5. Diagnostic socket
6. Oil level warning light
7. Instrument panel lighting bulbs
8. High beam warning light
9. Turn indicator warning light
10. Fuel level instrument
11. Instrument panel
12. NTC temperature sensor
13. Low fuel warning light
14. Light switch
15. Key switch
16. Turn indicator switch
17. Starter button
18. Front stop switch
19. Rear stop switch
ELE SYS - 52
Typhoon 125 4T (2010-) Electrical system
20. Rear left turn indicator

21. Rear light
22. License plate light
23. Rear right turn indicator
24. Start-up relay
25. Starter motor
26. Battery
27. Main fuse
28. Auxiliary fuses
29. Coil
30. Spark plug
31. Throttle sensor
32. CDI control unit
33. Automatic starter
34. Carburettor PTC heater
35. Regulator
36. Oil pressure sensor
37. Pick-up
38. Generator
39. Front right turn indicator
40. High beam light
41. Front position light
42. Low beam light
43. Front left turn indicator
44. Front headlamp
45. Ground point on chassis
Colours of the electrical cables:
B = White
Bl = Blue
G = Yellow
Mr = Brown
N = Black
BV = White-Green
GN = Yellow-Black
Gr = Grey
Rs = Pink
R = Red
Vi = Violet
ELE SYS - 53
V = Green
VN = Green-Black
BN = Black-White
BBl = White-Blue
GV = Yellow-Green
Ar = Orange
Az = Sky blue
GrBl = Grey-Blue
GrN = Grey-Black
RBl = Red-Blue
GR =Yellow-Red
BlN = Blue-Black
ELE SYS - 54
Components arrangement
ELE SYS - 55
1. Air temperature sensor - Remove the leg

shield, as described in the «BODYWORK» chap-
ter to reach it.
2. Voltage regulator - 3. Coil - Remove the rear

central cover to reach it.
4. Battery - 5. Main fuse - Lift the saddle and re-

move the cover to reach it.
6. Start-up solenoid - Remove the side fairings to

reach it.
ELE SYS - 56
7. Secondary fuses - Open the glove-box lid to

reach them.
8. Horn - Remove the footrest to reach it.
9. Ignition switch - Remove the leg shield back

plate to reach it.
10. Fuel level transmitter - 11. Diagnosis con-

nector - Remove the battery inspection cover to
reach them.
ELE SYS - 57
12. Oil pressure sensor - 13. Engine speed sen-

sor - Remove the fan cover cap to reach them, as
described in the ENGINE chapter.
14. Starter motor - Remove the helmet compart-

ment to reach it.
15. CDI control unit - Remove the leg shield to

reach it.
16. Right brake switch - 17. Left brake switch -

Remove the front handlebar cover to reach them.
ELE SYS - 58
18. Automatic starter - 19. PTC heater - 20.

Throttle position sensor - Remove the helmet
compartment to reach them.
21. Horn button - 22. Light switch - 23. Turn in-

dicator switch - They are fixed inside the rear
handlebar cover, on the left-hand side.
24. Engine starter button - It is fixed inside the

rear handlebar cover, on the right-hand side.
ELE SYS - 59
Ground points
- On the vehicle there is a chassis ground point,

beneath the rear central cover.
• On the engine there is a ground point

on the starter motor.
Electrical system installation
Front side
1. Upper branch of the main cable harness

2. Front brake stop switch cable
3. Engine starter button cable
4. Front left turn indicator cable
5. Front right turn indicator cable
6. Rear brake stop switch cable
7. Instrument panel connectors
8. Light switch connector
ELE SYS - 60
9. Central branch of the main cable harness

10. Air temperature sensor connector
11. Ignition switch connector
12. Front light cable
13. Secondary fuse cable
14. CDI control unit cable
15. Horn cable

16. Transverse branch of the main cable harness
ELE SYS - 61
Back side
17. Ground cable on chassis

18. Regulator cable - chassis ground
19. Coil cable
20. Spark plug cable
21. Branch of devices on engine
22. Rear branch of the main cable harness
23. Start-up solenoid cable

24. Rear lights and fuel level transmitter connect-
ing branch
25. Battery positive and main fuse connecting ca-
ble
26. Battery negative connecting cable
27. Diagnosis connector cable
28. Fuel level transmitter cable
ELE SYS - 62
29. Battery positive lead

30. Main fuse connecting cable
31. Battery negative lead
32. Diagnosis connector
33. Rear right turn indicator cable
34. Rear left turn indicator cable
35. Rear light cable
36. License plate lamp cable
37. Ground cable on engine

38. Starter motor positive wire
39. Connector for stator, pick-up and oil pressure
sensor
40. Branch connecting devices on carburettor
41. Automatic starter connector
42. PTC resistor connector
43. Throttle position potentiometer connecting ca-
ble
ELE SYS - 63
Conceptual diagrams
Ignition
Key:
5. Diagnostic socket
15. Key switch
26. Battery
27. Main fuse
28. Auxiliary fuses
29. Coil
ELE SYS - 64
30. Spark plug

31. Throttle sensor
37. Pick-up
Battery recharge and starting
Key:
15. Key switch
17. Starter button
21. Rear light
24. Start-up relay
25. Starter motor
26. Battery
27. Main fuse
28. Auxiliary fuses
35. Regulator
38. Generator
ELE SYS - 65
Level indicators and enable signals section
Key:
4. Fuel level transmitter
6. Oil level warning light
10. Fuel level instrument
12. NTC temperature sensor
13. Low fuel warning light
15. Key switch
26. Battery
27. Main fuse
28. Auxiliary fuses
36. Oil pressure sensor
ELE SYS - 66
Instruments and warning lights control board
A= High beam warning light;

B = Oil pressure warning light;
C= Turn indicator warning light;
D= Low fuel warning light;
E = Odometer;
F= Rpm indicator;
G= Fuel gauge
LIGHT BULBS TABLE

1 High/low beam light bulb Type: Halogen (H8)
Power: 12V - 35W
Quantity: 2
2 Front side light bulb Type: All glass
Power: 12V 3W
Quantity: 2
3 Instrument panel bulb, indicator warning lights, oil pres- Type: All glass
sure and high beams Power: 12V - 1.2W
Quantity: 5
4 Front turn indicator light bulb Type: SPHERICAL (amber colour)
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
5 Rear turn indicator light bulb Type: SPHERICAL (amber colour)
Power: 12V - 10W
Quantity: 1 RHS + 1 LHS
6 Stop light/rear daylight running light bulb Type: ALL GLASS (twin-filament)
Power: 12V - 21/5W
Quantity: 1
7 License plate bulb Type: All glass
Power: 12V - 3W
Quantity: 1
ELE SYS - 67
Devices and accessories
Key:
2. Horn
3. Horn button
15. Key switch
26. Battery
27. Main fuse
28. Auxiliary fuses
33. Automatic starter
34. Carburettor PTC heater
ELE SYS - 68
Lights and turn indicators
Key:
7. Instrument panel lighting bulbs
8. High beam warning light
9. Turn indicator warning light
14. Light switch
15. Key switch
16. Turn indicator switch
20. Rear left turn indicator
21. Rear light
22. License plate light
23. Rear right turn indicator
26. Battery
27. Main fuse
28. Auxiliary fuses
ELE SYS - 69

39. Front right turn indicator
40. High beam light
41. Front position light
42. Low beam light
43. Front left turn indicator
44. Front headlamp
Checks and inspections
Ignition circuit
All the control operations of the system that entail disconnecting cables (to check connections and the
devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls
might be irretrievably damaged.
The battery provides the basic power supply. The system is adjusted so that the start-up system im-
mediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; therefore, 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:
- Check the Pick-Up.
The check includes the Pick-Up and its power line.
Disconnect the control unit connector and meas-
ure the resistance between terminal No. 10 (Blue/
Yellow) and terminal No. 12 (Blue).
If the value measured is incorrect, repeat the
check directly on the component. Disconnect the
pick-up connector on the engine and measure the
resistance between the pin corresponding to the
ELE SYS - 70
Blue-Yellow cable of the wiring and the ground

connection on the engine.
If correct values are detected, check that the cable
is not interrupted.
Pick-up resistance value
~ 130 Ohm
- HV primary coil check

Disconnect the control unit connector and check
that the cable between terminal No. 4 (White/Vio-
let) and terminal No. 12 (Blue) is not interrupted
(see figure).
If non-conforming values are measured, check
again the HV coil primary directly on the positive
and negative terminals.
If the values are correct, repair the cable harness
or reset the connections; otherwise, replace the
HV coil
High voltage coil primary resistance value
High voltage coil primary resistance value: ~ 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.
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm
ELE SYS - 71
- H.V. coil
With the control unit and HV coil connected to the
circuit, measure the voltage of the coil primary dur-
ing the start-up test with the voltage peak adaptor
and connect 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.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS
BLACK.
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
Battery recharge circuit
The charging circuit consists of three-phase alternator and a permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive terminal passing through
the 20A main protection fuse.
This system therefore requires no connection to the ignition switch.
The three-phase alternator provides good recharge power and at low revs a good compromise is ach-
ieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Specific tooling
020334Y Multiple battery charger
Switches check
To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.
KEY
Ar:Orange Az:Light Blue Bi:White Bl:Blue Gi:Yellow Gr:Grey Ma: Brown Ne: Black Ro:Pink Rs:Red
Ve:Green Vi:Purple
ELE SYS - 72
STARTER BUTTON
LIGHT SWITCH
FLASHER SWITCH
HORN BUTTON
ELE SYS - 73
Stator check
Disconnect the connector from the voltage regu-

lator and check there is continuity between any
yellow cable and the other two cables.
Ohm value:
1 ± 1 Ohm
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 rep-
etitions of incorrect values replace the stator or
repair the wiring.
Voltage regulator check
With a perfectly charged battery and lights off,

measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 14.5 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
ELE SYS - 74
Recharge system voltage check
Connect the ammeter induction clamp to the volt-

age regulator positive terminal (Red/Orange),
measure the battery voltage and turning on the
vehicle lights with the engine off, wait for the volt-
age to settle at about 12 Volt. Start the engine and
measure the current generated by the system with
the lights on and a high running engine.
In case the generated current value is lower than
8A, repeat the test using a new regulator and/sta-
tor alternatively.
Characteristic
Distributed current
13A at 6000 rpm
Starter motor
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
If it does not work:
- Check the continuity of the Green/Red cable between the 7.5A fuse (B) and stop buttons.
- Check the continuity between the starter button Green/Red cable and the stop button Green/Yellow
cables.
- Check continuity between the Yellow/Red cable between the starter button and the start-up solenoid.
- Check that the Red cable between the battery and the start-up solenoid, and the latter and the starter
motor are not interrupted.
- Check the start-up solenoid.
- Check the contacts of the ignition switch, the starter button and the stop buttons.
- Check the efficiency of the fuses.
- Check that the starter motor is grounded.
- If all the tests are positive, replace the starter motor.
ELE SYS - 75
Horn control
KEY
1. Battery
2. Main fuse (A) 20A
3. Ignition switch contacts
4. Secondary fuse (C) 15A
5. Horn button
6. Horn
WARNING
DISCONNECTED.
If the horn does not work:
- Check the efficiency of the fuses.
- Check the ignition switch and the horn button contacts.
- If the components are not damaged, check wiring for continuity.
- Check the continuity of the Green cable which connects the horn button to 15A fuse (C).
- Check the continuity of the Grey cable which connects the switch to the horn.
- If all the tests are positive, replace the horn.
ELE SYS - 76
Choke Inspection
Refer to the engine section to check the resistance

and operating conditions of the component. As re-
gards voltage supply, keep the connector connec-
ted to the system and check that the two terminals
receive battery voltage when the engine is on
(see figure).
If no voltage is detected, connect the multimeter
negative probe to the ground lead and the positive
probe to the automatic starter Yellow cable; with
the ignition switch set to "ON" check whether there
is battery voltage; if there is no voltage, check the
wiring connections to the ignition switch.
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 and check there is voltage
when the multimeter positive terminal is connected to terminal No. 9 (Green/Red) and the negative one
to terminal No. 11 (Green/Black).
Replace the control unit if there is no voltage; otherwise, check the wiring connections between the
starter and the control unit.
Turn signals system check

WARNING
DISCONNECTED.
Check that bulb operates properly.
Check continuity of the Blue-Black cable between the CDI control unit and the turn indicators switch.
Check that the turn indicator switch works properly.
Check continuity of the Red and Blue cables which connect the switch to the bulbs.
level indicators
WARNING
DISCONNECTED.
ELE SYS - 77
If faults are detected:

- With a multimeter, check resistance values be-
tween the Grey-Green cable and the Blue cable of
the fuel level transmitter by moving the arm with
the float.
- If the transmitter operates correctly but the indi-
cation on the instrument panel is not exact, check
that the cable harnesses between them are not in-
terrupted.
- Check continuity of the Green cable which con-
nects the instrument panel to the 15A secondary
fuse (C).
- Check continuity of the Grey/Green cable which
connects the instrument panel to the probe check-
ing fuel level.
Resistance value when the tank is full
~ 7.4 Ω
Resistance value when the tank is empty
~ 101 Ω
Fuses
The electrical system is protected by a main fuse

(A) connected on the left-hand side of the helmet
compartment next to the battery. For access it is
necessary to remove the battery cover and the
transparent protection over the fuse block. Starter
circuit, light circuit, horn and instrument panel are
protected by two secondary fuses (B) and (C) lo-
cated inside the glove-box.
CAUTION
BEFORE REPLACING THE BLOWN FUSE, SEARCH AND
SOLVE THE PROBLEM THAT CAUSED IT TO BLOW.
NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE
OF A DIFFERENT RATING THAN THAT SPECIFIED OR US-
ING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF
ELECTRICAL WIRE).
ELE SYS - 78
FUSE CHART
1 FUSE A Capacity:20A
Protected circuits: Recharge circuit, oil pressure sen-
sor, oil pressure warning light.
2 Fuse B Capacity:7.5 A
Protected circuits: Start-up circuit, starter motor, stop
light bulb, ECU power supply.
3 Fuse C Capacity:15A
Protected circuits: Rear light bulb, license plate light
bulb, turn indicator bulb, turn indicator warning light, fuel
gauge, instrument panel lighting bulb, horn, low beam
bulb, high beam bulb, high beam warning light.
Sealed battery
Commissioning sealed batteries
INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT

1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If the voltage exceeds 12.60 V, the battery may 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 equal to 14.40 - 14.70V
-Initial charge voltage equal to 0.3 - 0.5 for nominal capacity
-Duration of the charge: 10 - 12 h recommended
Minimum 6 h
ELE SYS - 79
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
-Duration of the charge: 5 h
WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE 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 CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Battery installation
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)

WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY
COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR
APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK. MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.
2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.
ELE SYS - 80
3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.
4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note: If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container
two or three times. Do not remove the container from the battery.
5) Take out the container.
Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte
remains in the container. Only once the container is completely empty, gently remove the container
itself from the battery. Leave the battery to rest, without sealing the six cells, for at least 1 hour before
charging.
6) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
The dry charge battery MF like the completely loa-
ded YTX, must have a zero load voltage between
12.8 - 13.15 V Bring the battery to full charge, us-
ing the 020648Y battery charger:
a - select the type of battery with the red switch on
the left of the panel battery charger panel
b - select NEW on the yellow timer
ELE SYS - 81
c - connect the clamps of the battery charger to the

battery poles (black clamp to negative pole (-) and
red clamp to positive pole (+)).
d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.
f - Check the ignition of the green LED indicated

with a red arrow in figure.
g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place
ELE SYS - 82
h - Disconnect the clamps from the battery and

check the voltage, if voltages are detected of less
than 12.8 V, proceed with a new recharge of the
battery starting from point c of the recharge pro-
cedure of the new battery, otherwise go to point i
i - The battery is now properly activated, disconnect the battery charger from the power supply and
unplug the terminals from the battery.
7) Battery closing.
Insert the airtight cover strips into the filling holes.
Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery.
Note: To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Assembly procedure of the battery on the vehicle.
ELE SYS - 83
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Typhoon 125 4T (2010-) Engine from vehicle
Exhaust assy. Removal
- Remove the 2 fixing nuts from the manifold to the

head
- Undo the 2 screws fixing the silencer to the hous-

ing; then remove the whole muffler paying atten-
tion to the interference between its supporting
bracket and the cooling cover.

Nut fixing silencer to cylinder head 16 - 18 Si-
lencer to crankcase fixing screws 24 to 27
Removal of the engine from the vehicle
- Remove the side fairings.

- Remove the helmet compartment.
- Remove the full silencer unit.
- Remove the fastening screw of the rear brake
transmission shown in the photograph and slide off
the cable of the retainer brackets.
ENG VE - 85
Engine from vehicle Typhoon 125 4T (2010-)
- Loosen the throttle control cables by acting on

the carburettor set screws and slide them off the
pulley.
See also
- Remove the fuel supply pipe from the carburettor
- Remove the fuel valve low-pressure pipe from the

manifold as shown in the photograph
- Remove the flywheel wiring connector, the

ground terminal and the starter motor positive ca-
ble indicated in the figure
ENG VE - 86
Typhoon 125 4T (2010-) Engine from vehicle
- Remove the clamp retaining the starter wiring

and the heater indicated in the figure
- Disconnect the automatic starter and carburettor

heater connectors.
- Keep the engine-swinging arm pin nut blocked on

the left-hand side of the vehicle and undo the pin
from the opposite side.
ENG VE - 87
Engine from vehicle Typhoon 125 4T (2010-)
- Adequately support the vehicle (i.e. with a jack)

and remove the engine-swinging arm pin and the
shock absorber lower mount.
The engine is now free.
ENG VE - 88
INDEX OF TOPICS
ENGINE ENG
Engine Typhoon 125 4T (2010-)
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary

to remove the rear plastic cover first by inserting a
screwdriver in the corresponding slotted holes.
Using the clutch housing lock wrench, remove the
driven pulley axle locking nut and recover the
washer.
- Remove the cap/dipstick from the engine oil filling
hole.
- Remove the ten screws.
- Remove the transmission cover. If this operation
is performed directly on the vehicle, it is necessary
to remove the air filter housing retainers.
Specific tooling
Air duct
- Unscrew the Torx screws fixing the air duct bulk-

head and remove the bulkhead.
- Remove the 3 screws, then take out the duct as
well as the filter.
ENG - 90
Typhoon 125 4T (2010-) Engine
Air duct filter
- Unscrew the two fixing screws and slide off the

filter.
- Clean with water and milid soap.
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.

- Use the specific tools to remove the bearing from
the crankcase.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAM-
AGING THE COVER PAINT.
Specific tooling
ENG - 91
Refitting the driven pulley shaft bearing
- Heat up the crankcase inside with the hot air gun.

- Insert the bearing in its housing, refit the Seeger
ring.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020151Y Air heater
020412Y 15-mm guide
Removing the driven pulley
- Remove the spacer, the clutch housing and the

whole driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Inspecting the clutch drum
- Make sure that the clutch housing is not worn or

damaged.
- Measure the clutch housing inside diameter.
Characteristic
Clutch housing max. value
Max. value: Ø 134.5 mm
clutch housing standard value
Standard value: Ø 134 - 134.2 mm
ENG - 92
Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft unit on the support to check
the crankshaft alignment.
- Using a dial gauge and the magnetic base, meas-

ure the bell eccentricity.
- Repeat the measurement at 3 positions (Central,
internal, external).
- In case of faults, replace the bell.
Specific tooling
alignment
Characteristic
clutch housing check: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Removing the clutch
- Prepare the locking tool for the driven pulley with

the pins half-screwed in the tool set to «C».
- Introduce the adapter ring 11 with the chamfering
facing the inside of the tool.
ENG - 93
- Fit the driven pulley unit in the tool so as the bolt

get into the masses clutch support holes. After-
wards make the support screw make contact with
a minimum force.
- Using the specific wrench, inserted 46 mm from
the side, remove the clutch central locking nut.
- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE
TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE
SPECIFIC TOOL.
Specific tooling
020444Y Tool for installing/removing clutch on/from driven pulley
020444Y011 adapter ring
020444Y009 wrench 46 x 55
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must exhibit no traces of lubricants;
in that case, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL FACING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID
VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
ENG - 94
Pin retaining collar
- Simultaneously turn and pull the collar manually

to remove it.
N.B.
USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL-
TY.
N.B.
BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO
FAR TO AVOID DAMAGE THAT COULD COMPROMISE
THE O-RING SEAL.
Inspecting the driven fixed half-pulley
- Measure the outside diameter of the pulley bush-

ing.
Characteristic
Minimum diameter permitted
Ø 40.96 mm
Standard diameter
Ø 40.965 mm
Removing the driven half-pulley bearing
- Remove the retainer ring using two flat blade

screwdrivers.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Remove the roller bearing using the specific ex-
tractor.
N.B.
REST THE DRIVEN PULLEY ON A WOODEN SURFACE TO
AVOID DAMAGING ITS THREADED BUSHING. ALSO DO
THIS UPON REMOVAL.
Specific tooling
020439Y 17-mm guide
ENG - 95
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two O-

rings.
- Measure the inside diameter of the mobile half-
pulley bushing.
Characteristic
Minimum admissible diameter:
Ø 41.08 mm
Standard diameter
Ø 41.035 mm
Refitting the driven half-pulley bearing
- Assemble a new roller bearing using the specific

punch, fit the bearing with the label facing outward
and insert it completely up to the punch on the half-
pulley.
N.B.
REST THE DRIVEN PULLEY ON A WOODEN SURFACE TO
AVOID DAMAGING ITS THREADED BUSHING. ALSO DO
THIS UPON REMOVAL.
Specific tooling
020424Y Driven pulley roller casing fitting
punch
ENG - 96
- To assemble the new ball bearing, insert it fully

down in its seat with the specific punch and finally
fit the seeger ring.
Specific tooling
020439Y 17-mm guide
Refitting the driven pulley
- Check that the faying surfaces between the 2

half-pulleys and the belt do not show any signs of
wear, scoring and grease.
- Insert the new oil seals and O-rings on the mov-
able half-pulley.
- Assemble the half-pulley on the ringlet with the
appropriate protection sheath.
- Make sure the pins and collar are not worn, re-
assemble the pins and collar.
- Use a greaser with a curved spout to lubricate the
driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes
inside the bushing until grease comes out of the
opposite hole. This operation is necessary to avoid
the presence of grease beyond the O-rings.
Specific tooling
020263Y Driven pulley assembly sheath
MONTBLANC MOLYBDENUM GREASE MON-
TBLANC MOLYBDENUM GREASE
Molybdenum disulphide grease, ivory coloured;
Specification TL 9150 066, symbol NATO G 460
ENG - 97
Inspecting the clutch spring
- Measure the length of the spring when it is re-

laxed.
Characteristic
Standard length:
106 mm
Acceptable limit after use
102.5 mm (4.035 in)
Refitting the clutch
- Check the thickness of the clutch mass friction

material.
-The masses must not show traces of lubricants;
otherwise, check the driven pulley unit.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-
ENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN
CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS SO AS TO
PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted:
1 mm
- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring No. 11 with the cham-
fering facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the torque server closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the drive belt into the pulley unit according
to their direction of rotation.
ENG - 98
- Insert the pulley unit with the belt into the tool.
- 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 accord-
ing 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 and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
N.B.
DURING THE SPRING PRE-LOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED CONTACTING THE CLUTCH.
Specific tooling
020444Y Tool for installing/removing clutch
on/from driven pulley
020444Y011 adapter ring
020444Y009 wrench 46 x 55

Nut locking clutch unit on pulley 55 - 60 Nm
ENG - 99
Refitting the driven pulley
- Reassemble the clutch housing and spacer.
Drive-belt
- Make sure the drive belt is not damaged and does not show abnormal wear.
- Replace according to the scheduled maintenance table.
Removing the driving pulley
- Lock the driving pulley with the specific tool as

shown in the figure. - Disassemble the central nut
and the cup washer, remove the drive and the 2
washers. - Remove the stationary half pulley and
the steel washer.
Specific tooling
- Remove the belt and slide the movable half-pul-

ley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide sliders.
Inspecting the rollers case
- Check that the internal bushing is not abnormally worn and measure inner diameter.
N.B.
DO NOT LUBRICATE OR CLEAN THE BUSHING.
ENG - 100
BUSHING ROLLER HOUSING

Maximum allowable diameter Ø 26.121 mm
Standard diameter Ø 26+0 +0.021 mm
BUSH SLIDE PULLEY

Minimum diameter permitted Ø 25.950 mm
Standard diameter Ø 26-0.020 -0.041 mm
CVT ROLLERS
Minimum diameter permitted Ø 18.5 mm
Standard diameter Ø 26±0.1 mm
- Check the guide shoes for the variator back-plate

are not worn.
- Check there is no wear in the roller housing, and
the surfaces in contact with the belt on either of the
pulley halves.
- Pre-assemble the movable half-pulley with the

roller contrast plate by placing the rollers as shown
in the figure, that is, during insertion, the closed
side should be on the left side of the pulley thrust.
- Mount the complete bushing unit on the crank-
shaft.
ENG - 101
Refitting the driving pulley
- Reassemble the parts of the unit (internal lining,

fixed half-pulley, external lining, drive and nut),
spread threadlock on the thread and screw the nut
to the prescribed torque.
-Avoid the half-pulley rotation using a calliper
spanner
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT.
Specific tooling
Loctite 243 Medium strength thread-locking
sealant.
Blue

Driver pulley nut 75 - 83
Refitting the transmission cover
- Check that there are 2 alignment dowels and that

the sealing gasket for the oil sump on the trans-
mission cover is adequately fitted.
- Replace the cover and tighten the 10 screws to
the specified torque.
- Refit the oil loading cap/bar.
- Refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
ENG - 102
- Refit the plastic cover.
Specific tooling

Transmission cover screws 11 to 13 Driven pul-
ley shaft nut 54 to 60
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage tap

located inside the hub cover
- Remove the brake shoe and relevant spring
- Remove the 7 flanged screws as shown in the
figure.
- Remove the rubber cover and the brake shoes
lever sliding unscrewing the relevant retaining
screw to reach the rear of the cover
- Take off the hub cover and relevant gaskets
Removing the wheel axle
Remove the intermediate gear and the complete

hub cover.
ENG - 103
Removing the hub bearings

- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are de-
tected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y013 Calliper to extract ø 15-mm bear-
ings
Removing the wheel axle bearings

- Take out the clip on the outside of the hub cover.
- Remove the bearing with the adequate tools ad-
equately supporting the hub cover, as shown in the
figure.
Specific tooling
020364Y 25-mm guide
With the appropriate tools, remove the oil seal as

shown in the figure.
Specific tooling
Removing the driven pulley shaft bearing

If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven
pulley.
- Extract the driven pulley shaft from its bearing.
- Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.
- Remove the Seeger ring shown in the figure
ENG - 104
With the sectional punch, remove the driven pulley

shaft bearing.
Specific tooling
020363Y 20-mm guide
See also
Removing the driven pulley
Inspecting the hub shaft
- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- If faults are found, replace the damaged compo-
nents.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted. - Check the load capacity of the bearings and
the brake camshaft. - If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Heat up the parts using the specific heat gun.
Specific tooling
020151Y Air heater
- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools
Specific tooling
ENG - 105
- Refit the Seeger ring with the opening facing the

bearing as shown in the figure and fit a new oil seal
flush with the crankcase.
Refitting the wheel axle bearing
- Heat up the parts using the specific heat gun
Specific tooling
020151Y Air heater
-The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide
• Assemble the Seeger ring.

• Assemble the oil seal flush with the in-
ternal surface as shown in the figure to
the hub using the adequate tools and
with the seal lip towards the inside of
the hub.
Specific tooling
Refitting the hub cover bearings
- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the
specific heat gun.
Specific tooling
020151Y Air heater
ENG - 106
- The three 15 mm bearings must be fitted using

the appropriate tools.
Refitting the hub bearings
- Insert the cover prepared in the crankcase taking

care of inserting the gear of the pulley shaft on the
intermediary gear.
Refitting the ub cover
- Fit a new gasket together with the alignment

dowels.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Screw the 7 screws to the specified torque, po-
sitioning the support plate of the pipe in the posi-
tion shown in the figure.
- Remove the control pin of the shoe taking care
so as the long tooth coincides with the groove on
the control lever.

Rear hub cap screws 24 - 27
ENG - 107
Flywheel cover
Cooling hood
- Remove the SAS valve and the cylinder head

connecting pipe (see SAS valve).
- Remove the flywheel duct by undoing the four
fixing screws.
CAUTION
UPON REMOVAL SLIDE THE CONNECTOR OFF ITS FIT-
TING ON THE DUCT.
- Loosen the clamp and remove the carburettor

from the manifold.
-Remove the complete manifold acting on the 2
retainers as shown in the figure.
- Slide the access flap to the spark plug.

- Remove the two self threading screws, left and
right and the lateral left fixing screw on the crank-
case base.
- Take off the two caps from the thermal group.
- Remove the gasket seal of the housing on the
head.

Flywheel hood fixing screws 1 ÷ 2
ENG - 108
Cooling fan
- Remove the fan cover cap.

- Remove the cooling fan by acting on the three
fixings indicated in the figure.

Flywheel fan screws 3 to 4
Removing the stator
- Remove the magneto flywheel.

- Remove the electric terminal of the minimum oil
pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
Refitting the stator
- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.
- Place the cable harness as shown in the figure.
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE DOWEL AS
SHOWN IN THE DETAIL DRAWING.

Stator screw 3 - 4 Pick-up screw 3 to 4
ENG - 109
Flywheel and starting
Removing the starter motor
- Remove the two screws indicated in the figure.

- Take the starter motor out of its seat.
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper

spanner.
- Remove the nut.
CAUTION
USING A CALLIPER SPANNER OTHER THAN THE ONE
SUPPLIED COULD DAMAGE THE STATOR COILS.
Specific tooling
020565Y Flywheel lock calliper spanner
- Extract the flywheel with the extractor.
Specific tooling
008564Y Flywheel extractor
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-up control plate.
ENG - 110
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key

properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
to 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up mounting.
N.B.
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED.

Flywheel nut 52 - 58
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.

- Fit the starter motor on the crankcase and lock
the 2 screws to the specified torque.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.

Starter screws 11 to 13
Cylinder assy. and timing system
ENG - 111
Removing the timing system drive
- Remove the parts listed below first: transmission

cover, belt driving pulley, oil pump pulley cover and
pinion separator washer.
- Remove the tappet cover.
- Remove the central screw fastener and the au-

tomatic valve lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve
lifter unit and the automatic valve lifter unit and its
end of stroke washer.
- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
- Remove the inner hexagonal screw and the counterweight

- Remove the camshaft control pulley with its washer.
ENG - 112
- Remove the command sprocket wheel and the timing chain.

- Remove the screws indicated in the figure, the spacer bar and the tensioner slider.
The tensioner pad must be removed from the transmission side. As regards the lower chain guide slider,
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
See also
Transmission cover
Removing the driving pulley
Removal
Removing the cam shaft
- Remove the 2 screws and the camshaft retainer

shown in the diagram.
- Remove the cam shaft.
- Remove the pin of the rocking levers from the

flywheel side holes.
- Remove the rocking levers and the elastic wash-
er.
N.B.
MARK THE ROCKERS ASSEMBLE POSITION, SO AS TO
AVOID THE INVERSION OF INTAKE WITH THE EXHAUST.
ENG - 113
Removing the cylinder head
- Remove the spark plug.

- Remove the 2 side retainers indicated in the fig-
ure.
- Loosen the 4 head-cylinder fixing nuts in two or
three stages and in a criss-cross sequence.
- Remove the head, the 2 alignment dowels and
the gasket.
N.B.
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.
Removing the valves
- Using the specific tool fitted with the element

shown in the figure, remove the cotters, the caps
and the spring between the valves.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
- Remove the oil seals with the appropriate tool.

- Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
ENG - 114
Removing the cylinder - piston assy.
- Remove the chain guide slider.

- Remove the cylinder base gasket.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE
REMOVING THE CYLINDER.
- Remove the two retainer rings, the wrist pin and

the piston.
- Remove the 3 piston rings from the piston.
N.B.
BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR-
ING REMOVAL.
Inspecting the small end
- Measure the internal diameter of the connecting

rod small end using an internal micrometer.
N.B.
IF THE DIAMETER OF THE CONNECTING ROD SMALL
END EXCEEDS THE MAXIMUM DIAMETER ADMISSIBLE,
SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE
THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE
AND CRANKSHAFT" CHAPTER".
Characteristic
Connecting rod small end check-up: Maximum
diameter
15.030 mm
Connecting rod small end check-up: Standard
diameter
15+0.015+0.025 mm
ENG - 115
Inspecting the wrist pin
- Check the outer diameter of the gudgeon pin.
Characteristic
Standard pin diameter
14.996 - 15 mm
Ø 14.994 mm
- Calculate the piston pin coupling clearance.

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
Piston pin bore - standard diameter
Ø 15+0.001 +0.006
- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.
- Measure 36.5 mm from the piston crown's shown
in the figure.
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.
- Using a bore meter, measure the inner cylinder

diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
- Pistons and cylinders are classified into catego-
ries based on their diameter. The coupling is car-
ried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out:
0.001 in 0.05 mm
ENG - 116
- The cylinder rectifying operation should be car-

ried out with a surfacing that respects the original
angle.
- 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 consump-
tion and guarantees optimum performance.
- The pistons are oversized due to cylinder rectifi-
cation and are subdivided into three categories
1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They
are also classified into 4 categories A-A, B-B, C-
C, D-D.
Inspecting the piston
- Carefully clean the seal housings.

- Measure the coupling clearance between the sealing rings and the piston grooves using suitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in the table, replace the piston.
STANDARD COUPLING CLEARANCE

Top piston ring 0.025 - 0.070
Middle piston ring 0.015 - 0.060
oil scraper 0.015 - 0.060
MAXIMUM ADMITTED CLEARANCE AFTER USE

Top piston ring 0.080 mm
Middle piston ring 0.070 mm
oil scraper 0.070 mm
ENG - 117
Removing the piston
- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.
- Fit the pin retainer ring onto the appropriate tool.
Specific tooling
020430Y Tool for fitting the pin snap rings
- With the opening in position indicated on the tool,

take retainer ring in the closed position using the
punch.
- Fit the pin retainer ring using the plug as shown
in the figure
N.B.
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST
BE USED MANUALLY.
CAUTION
USING A HAMMER TO POSITION THE RINGS CAN DAM-
AGE THE LOCKING HOUSING.
ENG - 118
Refitting the piston rings
- Place the oil scraper spring on the piston.

- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the piston crown. The ta-
pered side of the middle piston ring should always
be facing away from the piston crown.
- Fit the middle piston ring with the identification
letter facing the piston crown. In any case, the step
must be facing opposite the piston crown.
- Fit the top piston ring with the word 'top' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
N.B.
SO AS TO OBTAIN THE BEST CONFIGURATION THE 2
SEALING RINGS ARE MADE WITH A CONTACT CONICAL
CYLINDER SECTION.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness

determined above.
- Using the fork support and the piston ring retain-
ing band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.
Specific tooling
020426Y Piston fitting fork
ENG - 119
020427Y Piston assembly band
Inspecting the cylinder head
- Using a trued bar check that the cylinder head

surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
Maximum admitted unevenness: Cylinder
head check
0.05 mm
STANDARD DIAMETER
Standard diameter A Ø 32.5 - 32.525
Standard diameter B Ø 20 - 20.021
Standard diameter C Ø 12 - 12.018
Inspecting the timing system components
- Check that the guide slider and the tensioner

slider are not worn out.
- Ensure that the camshaft drive pulley, the chain
assembly and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts; if the
chain, pinion or pulley are worn, replace the whole
assembly.
ENG - 120
- Remove the central screw and the tensioner

spring. Check that the one-way mechanism is not
worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.
Inspecting the valve sealings
- Measure the width of the sealing surface on the valve seats.
VALVE SEAL SURFACE

Intake valve - seal surface 2.4 - 2.8 mm
Exhaust valve - seal surface 2.2 - 2.6 mm
Inspecting the valve housings
- Remove any carbon formation from the valve guides.

- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights in the rocker arm push direction.
Characteristic
Standard drainage guide diameter
5.012 mm
Standard intake guide diameter
5.012 mm
ENG - 121
- If the width of the impression on the valve seat or

the diameter of the valve guide exceed the speci-
fied limits, replace the cylinder head.
- Check width of the impression on the valve seat
«V»
Characteristic
Wear limit:
Max. 1.6 mm.
Inspecting the valves
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
Characteristic
Minimum diameter admitted - Intake:
4.96 mm
Minimum diameter admitted - Exhaust:
4.95 mm
Standard clearance - Intake:
0.013 - 0.040 mm
Standard clearance - Exhaust:
0.025 - 0.052 mm
Maximum clearance admitted- Intake:
0.062 mm
Maximum clearance admitted - Exhaust:
0.072 mm
- Check that there are no signs of wear on the

contact surface with the articulated register termi-
nal.
- If the sealing surface on the valves is wider than
the specified limit, damaged in one or more points
or curved, replace the valve with a new one.
Characteristic
Standard valve length - Intake:
80.6 mm
Valve standard length: Exhaust
ENG - 122
79.6 mm
- If no faults are found during the above checks,

you can use the same valves. For best sealing re-
sults, it is advisable to grind the valves. Grind the
valves gently with a fine-grained lapping com-
pound. During grinding, keep the cylinder head in
a horizontal position. This will prevent the lapping
compound residues from penetrating between the
valve stem/guide coupling.
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT
KEEP ROTATING THE VALVE WHEN NO LAPPING COM-
POUND IS LEFT. CAREFULLY WASH THE CYLINDER
HEAD AND THE VALVES WITH A SUITABLE PRODUCT
FOR THE TYPE OF LAPPING COMPOUND BEING USED.
- Insert the valves into the cylinder head.

- Test the 2 valves alternatively.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.
- Check the unloaded springs length.
Characteristic
Valve spring length
33.9 - 34.4 mm
ENG - 123
Refitting the valves
- Lubricate the valve guides with engine oil.

- Place the lower caps of the valve spring on the
head.
- Use the punch to fit the 2 sealing rings one at a
time.
Specific tooling
020306Y Punch valve seal rings fitting
- Fit the valves, the springs and the spring retaining

caps. Using the appropriate tool with adapter 11,
compress the springs and insert the cotters in their
seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear

on the cams.
Characteristic
Standard diameter Bearing A
Ø: 32.5 mm -0.025 -0.050 mm
Standard diameter Bearing B
20 -0.020 -0.041 mm
Minimum admitted diameter bearing A
Ø: 32.440 mm
Minimum admitted diameter bearing B
Ø: 19.950 mm
Intake cam height
27.512 mm
Exhaust cam height
27.212 mm
ENG - 124
- Check there is no wear on the cam shaft retaining

plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
Characteristic
Maximum axial clearance admitted
0.42 mm
- Check there are no signs of wear on the auto-

matic valve lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifter spring has not yielded.
- Replace any defective or worn components.
- Check there are no signs of scoring or wear on

the rocking lever bolt.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
- Measure the internal diameter of each rocking
lever.
-Check that the elastic washer dedicated to the
axle clearance of the rocking levers is not worn. -
In case of failure, replace the damaged compo-
nents.
Characteristic
Ø 11.970 mm
Maximum diameter allowed
Ø 12.030 mm
Refitting the head and timing system components
- Fit the timing chain guide slider.

- Insert the head and cylinder alignment dowels, fit the head gasket and the head on the cylinder.
ENG - 125
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.

Nuts fixing head to cylinder 28 to 30
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

Head fixing screws (external) 11 to 13
- Fit the timing chain sprocket wheel on the crank-

shaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the tensioner pad by the cylinder head.
- Fit the spacer and the screw fastener.
- Fit the pin, the exhaust rocking lever, the spring
washer and the intake rocking lever.
- Lubricate the 2 rocking levers through the holes
at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams opposing the
rocking levers.
- Insert the retention plate and tighten the two

screws shown in the figure to the prescribed tor-
que.

Camshaft retention plate screw 5 - 6
ENG - 126
- Refit 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.
- While doing so, fit the chain onto the control cam-
shaft pulley and keep the reference 2V in corre-
spondence with the reference mark on the head.
- Fit the pulley onto the camshaft.
- Assemble the counterweight with the corre-
sponding fixing screw and tighten to the specified
torque.

Pressure reducer counterweight retainer 7 - 8.5
-Fit the end-stop ring on the automatic valve lifter

cam and fit the automatic valve lifter cam to the
cam shaft.
- Fit the automatic valve lifter return spring.
- During this operation the spring must be loaded
approximately 180°.
N.B.
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.
- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed tor-
que.

Camshaft pulley screw 12 - 14
- Set the tensioner cursor in the rest position.

- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed
torque.
ENG - 127

Tensioner fastening screws 11 to 13
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed
torque.

Timing chain tensioner central screw 5 to 6
- Adjust the valve clearance.
- Fit the spark plug
Recommended spark plug
NGK CR7EB
Electrode gap
0.6 ÷ 0.7 mm

- Assemble the casing sealing gasket on the head.
On the fitting direction, use the supplements on the
timing side as reference.
- Assemble the screw fixing the housing to the
crankcase to the specified torque and the 2 self-
tapping screws joining the half-shells.
- Take care that the gasket is well inserted in its
housing during the assembly stage.
- Place the spark plug access cap.

Flywheel air duct screw 3 - 4
- Fit the intake manifold and lock the 2 screws to
the specified torque.
- Fit the carburettor onto the intake manifold and
lock the clamp
N.B.
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT
ON THE MANIFOLD.

Head intake manifold screw 11 to 13
ENG - 128
- Refit the cylinder head cover, tightening the 4

clamping screws to the prescribed torque.
- Refit the fan and the housing.
- Reassemble the oil pump control, the chain com-
partment 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 transmis-
sion chapter.

Head cover screws 11 - 13
Crankcase - crankshaft
- Precautionary remove the following units:

transmission cover, driving pulley, driven pulley
and belt, rear hub cover, gears, bearings and oil
seals as described in the transmission chapter.
- Remove the oil sump, the by-pass, the chain
compartment cover and the oil pump as in the lu-
brication chapter.
- Remove the flywheel cover, the fan, the flywheel
and the stator as described in the magneto fly-
wheel chapter.
- Remove the oil filter and the oil pressure bulb.
- Remove the cylinder-piston-head unit as descri-
bed in the cylinder head timing system chapter.
- Remove the 2 retainers indicated in the figure
and the starter motor.
- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do
this, use a plate and a support with specific tool
dial gauge.
Specific tooling
020262Y Crankcase splitting plate
Characteristic
Standard clearance
ENG - 129
0.15 - 0.40 mm
Splitting the crankcase halves
Remove the 11 coupling screws to the crankcase.

- Separate the crankcase while keeping the crank-
shaft in one of the two halves of the crankcase.
Remove the crankshaft.
CAUTION
IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC-
CIDENTALLY FALL.
- Remove the coupling gasket of the crankcase

halves.
- Remove the two screws and the internal shield
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
- Remove the oil seal on the flywheel side.

- Remove the oil filter fitting shown in the diagram
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance
0.20 - 0.50 mm
ENG - 130
- Check the radial clearance on the connecting rod.

-Check the surfaces that limit the axial clearance
are not scored and measure the width of the crank-
shaft between these surfaces, as shown in the
diagram.
CAUTION
BE CAREFUL NOT TO LET THE MEASUREMENT BE AF-
FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard clearance
0.036 - 0.054 mm
- If the axial clearance between crankshaft and

crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
Characteristic
Distance between the shoulders
55.67 - 55.85 mm
- Check the diameters of both the bearings of the crankshaft in accordance with 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
Category 1 28.998 - 29.004
Category 2 28.004 to 29.010
ENG - 131
Inspecting the crankshaft alignment
To install the crankshaft on the support and to

measure the misalignment in the 4 points indicated
in figure.
- Check that the crankshaft cone, the tab seat, the
oil seal capacity, the toothed gear and the threa-
ded tangs are in good working order.
- In case of failures, replace the crankshaft.
The big end bushings cannot be replaced. For the
same reason, the connecting rod may not be re-
placed and, when cleaning the crankshaft, be very
careful that no impurities get in through the shaft's
lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE.
Specific tooling
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 132
Inspecting the crankcase halves
- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- On the transmission side crankcase half, take
particular care cleaning the housing and oil ducts
for the following components: the oil pump, the oil
by-pass valve, the main bushings and the cooling
jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the piston, which regulates the oil pressure.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
- On the flywheel side crankcase half, take partic-

ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.
N.B.
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 CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
- Inspect the mating surfaces on the crankcase

halves for scratches or deformation, taking partic-
ular with the surfaces that mate with the cylinder
and the mating surfaces between the crankcase
halves.
- Defects in the crankcase coupling gasket or the
surfaces indicated in the figure can cause a drop
in the oil pressure and affect the lubricating pres-
sure for the main bushings and the connecting rod.
ENG - 133
- Check the main bearing seats that limit axial

clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two half-
bearings, one with holes and channels for lubrica-
tion whereas the other is solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposite the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
- The oil feeding channel section is also affected
by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THIS POSITION OF THE BUSHINGS ON THE
CRANKCASE, FITTING IS FORCED ON STEEL RINGS IN-
SERTED IN THE CASTING OF BOTH CRANKCASE
HALVES.
Characteristic
Standard driving depth
1.35 - 1.6
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
ENG - 134
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
- The main bushings are subdivided into 3 thickness categories; see the table below:
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.
MAIN BEARINGS
B Blue
C Yellow
E Green
Refitting the crankcase halves
- Fit the internal shield by locking the two screws

to the prescribed torque.

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 - 6
- Fit the oil filter joint and tighten it to the prescribed

torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, to-
gether with the alignment dowels.

Oil filter on crankcase fitting 27 - 33
ENG - 135
- Lubricate the main bushings and insert the crank-

shaft in the transmission side crankcase half.
- Reassemble both crankcase halves.
- Fit the 11 screws and tighten them to the pre-
scribed torque.
N.B.
WHEN FITTING THE HALF CASING AND THE CRANK-
SHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREA-
DED TANGS.

Engine-crankcase coupling screws 11 to 13
- Lubricate the flywheel oil seal.
- Use the appropriate tool to assemble the oil seal.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the pre-filter on the engine with its corre-
sponding cover to the specific torque.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COU-
PLING GASKET ON THE CYLINDER PLANE, TO ENSURE
BETTER SEALING PERFORMANCE.
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSE-
QUENCE IN INADEQUATE OIL SEAL.
Specific tooling

Pre-filter cap 24 to 30
Lubrication
ENG - 136
Conceptual diagrams
ENG - 137
Oil pressure check
- After removing the fan cover duct as described in

the "Flywheel Cover" chapter, remove the electric
connection of the minimum oil pressure switch and
then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 to 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 to 4.2 atm.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the prescribed torque
and fit the flywheel cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER
CONDITION.
Characteristic
Minimum pressure admitted
3.2 atm.

Minimum oil pressure switch 12 - 14
Crankshaft oil seals
ENG - 138
Removal
- Remove the transmission cover and the com-

plete drive pulley beforehand
- Install the base of the appropriate tool on the oil

seal using the screws provided.
- Screw the threaded bar onto the base of the tool

and extract the oil seal.
Specific tooling
020622Y Transmission-side oil seal punch
Refitting
- Prepare the new oil seal, lubricating the sealing

lip. Warning: do not lubricate the surface for keying
onto the engine crankcase.
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ONTO THE
ENGINE CRANKCASE
ENG - 139
- Preassemble the oil seal with the appropriate

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
CAUTION
ORIENT THE OIL SEAL BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
SEAL. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL SEAL
SHEATH
- 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.
ENG - 140
- Use the nut to move the base of the tool until you
can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN
Assemble a new oil seal on the flywheel side using
the specific tool as shown in the photograph
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSE-
QUENCE IN INADEQUATE OIL SEAL.
Specific tooling
Oil pump
Removal
- Remove the chain cover acting on the 3 retaining

screws as shown in the figure and the relevant
copper washers.
- Extract the cover using the appropriate appen-
dages.
N.B.
WITH THE AIM OF AVOIDING DAMAGING THE APPEN-
DAGES PRACTICE A RUN PARALLEL TO CRANKSHAFT.
ENG - 141
- Remove the cover of the pump control pulley us-

ing the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
using a screwdriver inserted through one of its two
holes.
- Remove the central screw with cup washer, as

- Remove the chain with the pulley.
- Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as

- Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
retainer ring.
ENG - 142
- Using a feeler gauge, check the distance be-

tween the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted
0.12 mm
Measure the distance between the outer rotor and

the pump body; see figure.
Characteristic
Admissible limit clearance:
0.20 mm
Check the axial clearance of the rotors with a trued

bar as reference, as shown in the figure.
Characteristic
Limit values admitted:
0.09 mm
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 assembly.
- Fit the pulley to the pump, the central screw to
the specified torque and the cup washer.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
ENG - 143
N.B.
FIT THE CUP WASHER SO THAT ITS OUTER (CURVED)
RIM TOUCHES THE PULLEY.

Central screw 12 to 14 Nm Cover screws 0.7 to 0.9
Nm
Removing the oil sump
- Remove the oil filler plug, the transmission cover,

the complete drive pulley assembly with belt and
the sprocket wheel, as described in the Transmis-
sion chapter.
- Drain the oil from the sump as described above.
- Remove the 7 screws indicated in the figure and
the 2 rear brake transmission fixing brackets.
- Remove the spring, the by-pass piston and the
gasket shown in the second image.
Inspecting the by-pass valve
- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defec-
tive parts.
Characteristic
By-pass check up:Standard length
54.2 mm
ENG - 144
Refitting the oil sump
- Refit the by-pass piston in its housing.

- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake transmission mounting brack-
ets and the screws in the reverse order from which
they were removed.
- Tighten the screws to the prescribed torque.
- Refit the driving pulley assembly, the drive belt,
the sprocket wheel and the transmission cover, as
described in the "Transmission" chapter.
- When testing the lubrication system, refer to
the "Crankcase and Crankshaft" chapter, re-
garding lubrication of the connecting rod as-
sembly

Oil sump screws 11 to 13
SAS valve
Inspecting the one-way valve
- Remove the SAS valve.

- Provisionally assemble the rubber sleeve of the
SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rub-
ber sleeve as shown in the photograph.
- Set the pump to the low-pressure position (VAC-
UUM).
- Operate the pump slowly.
- Check that the one way valve allows the air to
pass through causing a slight vibration.
- Switch the pump to pressure mode (PRES-
SURE).
ENG - 145
- Operate the pump slowly and check if there is an

increase of pressure. A small leakage is consid-
ered to be normal.
If anomalies are detected, replace the pump.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN
RUBBER SLEEVE AND FILTER OVERHEATING
N.B.
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEAL-
ING
Specific tooling
Inspecting the cut-off
- Remove the SAS valve.

- Connect the MITYVAC pump in low-pressure
mode (VACUUM) to the CUT-OFF valve vacuum
intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept all the time.
- If a worn seal is detected, replace it.
- With a "T" bypass and flexible rubber hoses make
a parallel connection between the rubber sleeve
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump set to the low-pressure mode
(VACUUM).
- Using a pair of long flat pliers, choke the rubber
hose next to the valve.
- Operate the pump until vacuum is higher than 0.5
BAR.
- Release the hose and check how the vacuum re-
acts. - Under normal functioning conditions the
vacuum undergoes a slight fall and then readjusts.
Then there is a stage of gradual and slow loss of
vacuum up to a value of approx. 0.4 BAR. At this
point the valve opening and the sudden vacuum
resetting is detected.
ENG - 146
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 SILENCER). IN-
CORRECT 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
Fuel supply
- Disconnect the fuel supply and the suction taking

pipe from the carburettor.
- Check that there are no fuel leaks between the
two tubes.
- Close the fuel outlet pipe.
- By means of the MITYVAC pump apply 0.1 bar
of suction to the tap.
- Make sure that the suction is kept stable and that
and that there are no fuel leaks.
- Reconnect the vacuum pipe to the manifold.
- Position the fuel pipe with the outlet at the point
of the tap.
- Turn the engine by using the starter motor for five
seconds with the carburettor at minimum.
- Take up the fuel by means of a graded burette.
N.B.
THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR-
RECT NUMBER OF REVS OR BY THE WRONG POSITION
OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OB-
TAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-
ENG - 147
LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY

REDUCED FOR THE PURPOSE OF ENHANCING THE SUC-
TION PULSATION AND THEREBY GUARANTEE A CON-
STANT TAP FLOW RATE.
Specific tooling
Characteristic
Minimum flow rate
20 cc
- Completely empty the fuel tank.

- Remove the petrol delivery pipe and the low-
pressure pipe.
- Loosen the clip and remove the cock.
- Clean the tank and the filter of the cock with a
specific solvent.
- Refit the cock making sure that there is an O-
Ring.
- Turn the cock to the direction it had before it was
removed and block the clip.
N.B.
THE FILTER CAN BE UNSCREWED FROM THE COCK TO
FACILITATE CLEANING.
Removing the carburettor
- To detach the carburettor from the engine, it is

necessary to move the air filter and remove the
throttle control transmission, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the intake manifold, the
air delivery pipe to the diaphragm, the heater and
the intake fitting.
ENG - 148
With the multimeter, check if the potentiometer is

working correctly by placing the probes on both
contacts indicated in the photograph.
With throttle valve completely closed, the resist-
ance value should be approx. 1.3 kOhm.
With throttle valve completely open, the resistance
value should be approx. 4.05 kOhm.
- Remove the heater.
- Remove the protection, the bracket and the start-

er acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with

the gasket.
ENG - 149
- 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.
- Remove the vacuum valve together with the di-

aphragm.
ENG - 150
- Unscrew the bayonet joint 1/8 of a turn and re-

move, take out the spring and vacuum valve nee-
dle
- Remove the 4 screws indicated in the figure.
- Remove the chamber with the accelerating

pump, its control and gasket.
- Remove the oil pump seal.

- Remove the intake and exhaust valves of the in-
take pump from the tank
N.B.
CAUTION, THE ACCELERATION PUMP VALVES ARE
MADE UP OF NOZZLES, SPRING AND BALL.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP AND ITS
CONTROL.
ENG - 151
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.
- Remove the maximum nozzle
-Remove the maximum nozzle.
ENG - 152
-Remove diffuser.
- Remove the sprayer.

N.B.
WHEN CLEANING THE CARBURETTOR BODY REMOVE
THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY-
ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO
REMOVE IT AS THIS WILL ONLY DAMAGE IT.
-Remove the minimum nozzle.
ENG - 153
- Remove the minimum flow set screw and the

spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR
PROGRESSIONS AND INTAKE NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNEC-
TION SCREWS. THE FIXING SCREWS ARE CAULKED AF-
TER FITTING AND THEIR REMOVAL DAMAGES THE
SHAFT.
Refitting the carburettor
- Before refitting, wash the carburettor body accu-

rately with petrol and compressed air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
- For maximum circuit, check the air adjustment is

correct as shown in the figure.
ENG - 154
- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, exhaust
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 EXHAUST IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY-
ING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
- Check that the coupling surfaces, the chamber 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.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
ENG - 155
- Properly wash and blow the components of the

sprayer maximum circuit, the diffuser and the noz-
zle.
- 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 ab-
sorber 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 failures.
- Introduce the float with the rod on the fuel feeding tube side.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
ENG - 156
- Remove the drainage screw from the tank, wash

and blow it properly and make sure the accelera-
tion pump pipes are clean.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves fol-
lowing this order:
INTAKE VALVE (A)
• Spring
• Ball
• Nozzle
IN VALVE (M)
• Ball
• Spring
• Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING TO THE AC-
CELERATION 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 fas-
tening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
N.B.
MAKE SURE THE TANK GASKET IS CORRECTLY INTRO-
DUCED.
N.B.
AVOID DEFORMING THE ACCELERATION PUMP CON-
TROL ROCKER.
- 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.
- The screw final position should be determined by an exhaust fume analysis.

- Adjust the carburettor by turning the screw twice from the close position.
ENG - 157
Level check
- Place the carburettor inclined as shown in the

figure.
- 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 - 158
• Insert a transparent rubber pipe to the bleeding intake of the fuel tank.
• Keep the pipe up so that the ends are higher than the venturi pipe.
• Unscrew the bleed screw and stabilise the petrol level, then measure as shown in the dia-
gram.
ENG - 159
Inspecting the valve and needle
- Check that the tapered pin of the vacuum valve

does not show wear.
- Check that the depression valve does not show
threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has
hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve
housing.
- Reassemble the vacuum valve on the carburettor
body taking care that the tapered pin is inserted
into the sprayer.
N.B.
THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE
POSITION.
- 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.
ENG - 160
- Wash and blow dry the filter sponge of the am-

bient pressure intake.
- Reassemble the filter with its clamp.
- Wash and blow dry the starter support.

Assemble a new gasket on the carburettor body
and tighten the 2 fixing screws.
ENG - 161
Inspecting the automatic choke device
- Check that the automatic starter piston is not de-

formed or rusty.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not de-
formed.
- The starter must be more or less functional de-
pending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the am-
bient temperature.
- The starter should disconnect progressively by
means of electric heating.
- 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 possi-
ble.
- The correct warm up time depends on the ambi-
ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
- 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 CONNEC-
TED TO THE STARTER.
Characteristic
Check the Kehin automatic starter: Protrusion
value
ENG - 162
XX - XX mm at approx. 20°C
Check Max. protrusion of Kehin aut. starter
XXX - XXX mm
Check aut. Kehin Max. time starter
5 Min
Adjusting the idle
- The engine does not require frequent idle speed

adjustments, but it is essential to strictly follow cer-
tain rules when adjusting the idle speed.
- Before adjusting the carburettor make sure to re-
spect the lubrication requirements, valve clear-
ance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 mi-
nutes at approximately 50 kph.
- Connect the vehicle to the exhaust fumes analy-
ser inserting the probe into a sealed extension pipe
placed at the muffler exit end.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly pre-
pared for probes.
- Start the engine and before adjusting the idle
speed, make sure that the oil temperature is be-
tween 70÷80 °C.
- Using the rpm indicator or any other instrument
(020332y), adjust the idle screw to obtain 1600
rpm ÷ 1700 rpm.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE IF INADEQUATE RPM INDICATORS ARE USED.
CORRECT COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000
ENG - 163
ENG - 164
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions Typhoon 125 4T (2010-)
Front
Removing the front wheel
- Loosen the wheel axle lock nut, by keeping the

wheel axle blocked on the opposite side.
- Loosen the two wheel axle safety screws on the

fork leg, on the odometer gear side.
- Pull out the wheel axle.
SUSP - 166
Typhoon 125 4T (2010-) Suspensions
- Remove the front wheel.

- Slide off the odometer gear from the wheel hub.
CAUTION
DO NOT ACT ON THE FRONT BRAKE LEVER ONCE THE
FRONT WHEEL IS REMOVED. BY DOING SO, THE CAL-
LIPER PISTONS COULD COME OUT FROM THEIR HOUS-
ING AND ALSO THE BRAKE FLUID MIGHT SPILL OUT.
Front wheel hub overhaul
Check that the wheel bearings do not show signs

of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the bearing on the odometer drive side
using the pliers 14 and the bell detail 9.
Specific tooling
001467Y013 Calliper to extract ø 15-mm bear-
ings
SUSP - 167
- Remove the internal spacer.
- 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 odom-
eter drive side to permit the removal of the brake
disc side bearing and the spacer bushing.
Specific tooling
020456Y Ø 24 mm adaptor
020412Y 15-mm guide
SUSP - 168
- Heat the bearing seat on the side the brake disc

with the heat gun.
- Grease one side of the new bearing to make it

stay together with the adaptor.
- Insert the bearing using the punch consisting of

adaptor handle, 42x47 mm adaptor and 15 mm
guide, and drive it up to the stop.
- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the
stop.
Specific tooling
020412Y 15-mm guide
020201Y Spacer bushing driving tube
SUSP - 169
- Turn the wheel upside-down and insert the inner

spacer.
- Heat the bearing seat on the odometer drive side with the heat gun.
- Grease one side of the new bearing to make it

stay together with the adaptor.
- Insert the new bearing on the odometer drive side

by using a punch consisting of adaptor handle,
32x35 adaptor and 15 mm guide and drive it fully
home.
Specific tooling
020412Y 15-mm guide
SUSP - 170
WHEEL RIM INSPECTION

- Make sure that the rim is not deformed or
cracked. Replace it if necessary.
- Check wheel eccentricity. If tolerance limits are
exceeded, check the wheel rim and the bearings.
If necessary, replace the wheel.
Characteristic
Eccentricity limits:
Vertical: 2 mm
Horizontal: 2 mm
- Check the wheel balance.

- Check wheel on the wheel balancer and turn it several times, paying attention to its position when it
stops. If the wheel is steadily balanced, it will not always stop at the same point. If it always stops at the
same point, the wheel is not balanced and must be balanced. Place weights on the lightest part of the
wheel so that it does not stop any more at a particular point after being turned several times.
SUSP - 171
Refitting the front wheel
- First shift by 90° the inner stop of the odometer

drive with respect to the one on the wheel.
- Insert the wheel axle after greasing it from the

brake disc opposite side, centring the retainer on
the fork leg onto the projecting parts of the odom-
eter drive.
- Holding the wheel axle, lock the nut on the op-
posite side to the specified torque.
SUSP - 172
- Make the fork travel to adjust the fork legs on the

wheel axle.
- Lock the two safety screws located on the fork
leg to the specified torque, according to the se-
quence 1-2-1.

Front wheel axle nut 45 - 50 Safety screw on fork
leg 6 - 7
Handlebar
Removal
- Remove the front and rear handlebar covers.

- Detach the front brake pump from the handlebar.
- Disconnect the rear brake, throttle control and
odometer control cables.
- Remove the screw fixing the handlebar to the
steering tube.
- Remove the handlebar.
See also
Front handlebar cover
Rear handlebar cover
Front
brake pump
Refitting
- 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 specified torque.

Handlebar fixing screw (*) 45 - 50
SUSP - 173
(*) Lubricate the nut with engine oil before instal-

lation
Front fork
Removal
REMOVING THE STANCHIONS

- Remove the legshield.
- Remove the brake calliper.
- Remove circlip «7», the two screws «8» and slide
off the stanchion.
- Unscrew the upper cap «6».
- Remove the components including the spring.
- Drain the oil into a collecting container.
SUSP - 174
- Undo screw «3», remove the stanchion and the

piston.
See also
Legshield
Removal
Overhaul
STANCHION INSPECTION
- Check the sliding surface for scorings and/or
scratches.
- If the scorings are deep, replace the stanchion.
SLEEVE INSPECTION
- Check that it is not damaged and/or cracked.
- If there are signs of excessive wear or damage,
replace the affected component.
- Replace the oil seal «4» and the dust gaiter «5»
and fit it once you have lubricated their seat.
- Replace the O-ring on the inner cap «1»
- Replace sealing washer «2».
Refitting
- Refit the stanchion and the piston and tighten

screw «3» with its washer «2» to the specified tor-
que.
- Pour the recommended quantity of specific oil in-
to the stanchion unit.
- Insert the spring and the components.
- Tighten the upper cap «6» to the specified torque.
- Introduce the stanchion in the bottom yoke and
install the circlip «7».
SUSP - 175
- Push on the upper cap «6» until the circlip touch-

es the bottom yoke.
- Tighten the screws «8» to the prescribed torque.
Characteristic
Fork stem (oil level height without spring, com-
pressed fork)
85 mm

Fork clamp screw 20 to 25 Fork stanchion upper
cap 15 ÷ 30 Piston tightening fork lower screw
25 - 35
Steering column
Removal
SUSP - 176
- Position the vehicle on centre stand.

- Set a support under the vehicle in such a way that
the wheel is able to move freely and the vehicle
does not fall.
- Remove the handlebar.
- Remove the front brake calliper.
- Release the fork from the odometer cable and
from the front brake calliper pipe.
- Loosen the upper ring nut «1» and collect the
shim washer «2».
Specific tooling

Upper steering ring nut 30 to 36
- Remove the upper ring (or lower ring nut) «3» of
the upper bearing «A».
- Slide the fork and collect the cage with the balls
«4» of the upper bearing «A».

Lower steering ring nut 10 - 13 **
When the specified torque of the lower ring nut is reached, loosen by 90°.
See also
Removal
Legshield
Removal
- Remove the balls retainer «7» of the lower bear-

ing «B» from the steering tube.
- Wash carefully all the parts removed.

- To refit, carry out the removal operations but in reverse order.
SUSP - 177
- Appropriately lubricate the bearings with recommended products.
BEARING SEAT REPLACEMENT ON CHASSIS

- Only remove the seats if it is strictly necessary.
- Using the special tool remove the upper bearing
«A» seat «5» by putting the special tool into the
lower part of the headstock as indicated in the fig-
ure.
- Remove the lower bearing «B» seat «6» on the
headstock by inserting the punch from the top on
the headstock.
Specific tooling
from headstock
- Using the special tool, refit the upper «A» and

lower «B» bearing seats on the headstock.
Specific tooling
001330Y Tool for fitting steering seats
LOWER BEARING SEAT REPLACEMENT ON

FORK
Check the condition of the lower bearing «B» seat
«8» on the fork (steering tube). Replace if there are
faults.
- Support the fork properly.
- Using the special tool, remove the seat «8» on
the steering tube as shown in the photograph by
applying small mallet blows.
Specific tooling
from headstock
SUSP - 178
Always use a new seat on refitting.

- Using the special tool, refit the seat «8» with the
aid of a few mallet blows and bring it as far as the
stop shown in the photo.
Specific tooling
006029Y Punch for fitting steering bearing on
the steering tube
Steering bearing
CHECKING THE BEARINGS CLEARANCE

To check the steering, it is necessary to:
- Position the vehicle on the centre stand.
- Place a support under the motorcycle in such a
way that the front wheel is able to move freely and
the vehicle does not fall.
When carrying out this operation, pay attention not
to mistake the centre stand clearance with that of
the steering. Repeat this test many times before
deciding if the steering clearance must be adjus-
ted.
- Hold the fork sleeves and pull the fork forwards
and backwards, with the steering in forward posi-
tion.
- There should be no clearance forward or back-
ward. If there is clearance, the steering must be
adjusted.
ADJUSTING THE BEARING CLEARANCE

- Remove the front shield.
- Loosen the upper ring nut «1» using the specific
wrench.
- Screw in the lower ring nut «3» until the bearing
clearance is totally eliminated.
CAUTION
DO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT
«3» BECAUSE THE STEERING BEARINGS COULD GET
DAMAGED.
- Check clearance as described above. Make sure the front fork can move all long its stroke, from left
to right or vice versa, rotating freely and smoothly.
SUSP - 179
- Keep the lower ring nut «3» in position, by using a specific wrench and tighten the upper ring nut «1»
to the specified torque. Check again the bearings clearance.
Specific tooling

Lower steering ring nut 10 - 13 ** Upper steering ring nut 30 to 36
When the specified torque of the lower ring nut is reached, loosen by 90°.
See also
Legshield
Rear
Removing the rear wheel
- Park the vehicle on the centre stand.

- Remove the silencer.
- Use a screwdriver to remove the plastic cap.
- Remove the cotter pin.

- Remove the cap.
SUSP - 180
See also
- Pull the rear brake and keep it pulled with a

clamp.
- Unscrew the wheel fixing nut and collect the
washer.
- Take out the wheel from its housing.
- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.

Rear wheel axle 115
Swing-arm
Removal
- Rest the vehicle on its centre stand.

- Support the engine adequately.
- Unscrew the nut on the left-hand side of the en-
gine and slide off the bolt from the opposite side.
SUSP - 181
- Loosen the nut on the inside of the frame from

the left-hand side and remove the relevant pin.
- Remove the Seeger ring shown in the picture.

- Remove the helmet compartment.
- Slide off the support spring by using a normal
spring puller.
SUSP - 182
- Lower the front end of the engine to free the

swinging arm.
- Slide off the swinging arm from the right-hand
side of the vehicle.
- To replace the silent block it is necessary to re-
move the support bracket, after removing the
swinging arm and the side fairings.
- Unscrew the two indicated retainers and remove
the bracket with silent block from chassis.
- To remove the silent block from the bracket,
please use the specific tool.
Specific tooling
020271Y Tool for removing-fitting silent bloc

Engine arm pin - chassis arm 45.5 Silent block-
swinging arm retaining bolts 42.5
Overhaul
Regularly check the clearance of the swinging arm

retainer pins. To carry out these operations, pro-
ceed as follows:
- Position the vehicle on centre stand.
- Hold the rear wheel firmly and try to move it per-
pendicularly to the travel direction.
- If there is any clearance, check all the fastening
elements that connect the swinging arm to the en-
gine and chassis as well as the condition of the
silent block.
Shock absorbers
SUSP - 183
Removal

- Support the vehicle adequately.
- Undo the inner nut and slide off the shock-ab-
sorber to chassis upper fixing screw.
- Undo the inner nut and slide off the shock-ab-

sorber to engine lower fixing screw.
- Remove the shock absorber.
- To refit tighten the screws to the prescribed tight-
ening torque.

Shock absorber nut 22.5
See also
Side fairings
Centre-stand
- Support the vehicle adequately.

- Undo the nut on the left-hand side of the engine.
SUSP - 184
- Remove the stand pin and collect the return

springs.
- When refitting lubricate the pin and the springs with the specified grease and tighten the nut to the
specified tightening torque.

Centre stand pivot on engine 42.5
SUSP - 185
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Typhoon 125 4T (2010-) Braking system
Front brake calliper
Removal
- Check that the brake piping, gasket and fitting are

in good condition. If you see any oil on the brake
calliper and/or the components of the system, it is
necessary to replace them.
- Detach the oil brake pipe from the calliper; pour
the fluid inside a container.
- Remove the two clamps shown in the figure.
- Remove the brake calliper from the fork.
Refitting
- Refit the calliper on the support and tighten the

screws to the specified torque.
- Refit the tube complete with fitting with new cop-
per gaskets.
- Place the tube joint in the original position and
tighten it to the specified torque.
- Bleed the air from the system.

Brake fluid pipe-calliper fitting 20 to 25 Calliper
to fork tightening screw 20 to 25 Oil bleed
screw 8 - 12
See also
Front
Front brake disc
BRAK SYS - 187

Braking system Typhoon 125 4T (2010-)
Removal
Proceed as follows:
- remove the front wheel.
- Undo the five screws fixing the disc.
- Remove the brake disc.
Refitting
When refitting, position the disc correctly, following

the direction indicated on the same disc.

Disc tightening screw 8 to 12
Disc Inspection
- Check the disc thickness.
Characteristic
Disc minimum thickness:
3.5 mm
BRAK SYS - 188

• 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 other than that prescribed is
detected, remove the front wheel and
check how much the disc protrudes.
The size measured must be within 0.1
mm. If it is greater replace the disc and
conduct the test again.
• If the problem persists, check and re-
place the wheel rim if necessary.
Specific tooling
See also
Front brake pads
Removal
- Remove the brake calliper.

- Undo and remove the two screws indicated.
- Remove the pads.

- Remove the inner spring.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKAGE.
BRAK SYS - 189

See also
Front
brake calliper
- Check the thickness of the friction material. If

thinner than the minimum value, replace it.
Characteristic
Friction material minimum thickness
1.5 mm
- In case of uneven wear, replace the brake pads

when the friction material thickness difference is
0.5 mm.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY
ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
BRAK SYS - 190

Refitting
- To refit, carry out the disassembly operations in

the inverse order, fitting the inner spring correctly
and tightening the fixing screws to the specified
torque.

Brake pad fastening screw 15 - 20
Fill
Front
N.B.
IF THERE IS AIR IN THE HYDRAULIC SYSTEM IT WILL ABSORB THE MAXIMUM PART OF THE
MAIN CYLINDER FORCE OF THE BRAKES AND IN THIS WAY WILL REDUCE THE CALLIPER
PERFORMANCE DURING BRAKING. YOU CAN DETERMINE IF THERE IS AIR IN THE SYSTEM
IF YOU NOTICE THAT THE BRAKE CONTROL IS SOFTER AND THE BRAKES ARE LESS EFFI-
CIENT.
CAUTION
SINCE THESE CONDITIONS ARE EXTREMELY DANGEROUS FOR THE VEHICLE AND FOR THE
DRIVER, IT IS ABSOLUTELY NECESSARY TO BLEED THE HYDRAULIC SYSTEM AFTER RE-
FITTING THE BRAKES AND COMPLETING THE NORMAL MAINTENANCE.
- Once the bleed valve is closed, fill the system
with brake fluid to the maximum level.
-Undo the bleed screw.
-Apply the tube of the special tool to the bleed
screws.
When bleeding it is necessary to fill the oil tank in
continuation while working with a MITYVAC pump
on the bleed screws until no more air comes out of
the system.
The operation is finished when just oil comes out
of the bleed screws.
-Do up the bleed screw.
-When the operation is over, tighten up the oil
bleed screw to the prescribed torque.
N.B.
BRAK SYS - 191

IF AIR CONTINUES TO COME OUT DURING PURGING, EX-

AMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAUL-
TY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS
SEALS ON THE PUMP AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE MUST BE ON
THE STAND AND LEVEL.
N.B.
DURING BLEEDING FREQUENTLY CHECK THE LEVEL TO
PREVENT AIR GETTING INTO THE SYSTEM THROUGH
THE PUMP.
WARNING
BRAKE FLUID IS HYGROSCOPIC; WHICH MEANS THAT IT
ABSORBS MOISTURE FROM THE SURROUNDING AIR.
IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A
GIVEN VALUE, BRAKING WILL BE INEFFICIENT.
THEREFORE, ALWAYS USE FLUID FROM SEALED CON-
TAINERS.
UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS
YOU SHOULD CHANGE THIS FLUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/OR IN
HARSH CONDITIONS, CHANGE THE FLUID MORE FRE-
QUENTLY.
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.
Specific tooling
DOT 4 brake fluid Synthetic brake fluid.
SAE J 1703; FMVSS 116; ISO 4925; CUNA NC
956 DOT4

Oil bleed screw 8 - 12
Front brake pump
- Remove the front and rear handlebar cover.

- Disconnect the tube, collecting the brake oil in a
container.
BRAK SYS - 192

- Operate on the two U bolt clamps (see figure).

- On refitting, perform the operation in reverse.
- Tighten the hydraulic line to the prescribed torque
and then fill and purge the system.

Brake fluid hose-pump fitting 20 - 25 Pump U
bolt screw 8
See also
Rear drum brake
Drum brake adjustment

Regulate the point where the rear drum brake in-
tervenes, using the adjustment indicated in the
figure.
With the brake lever at rest, the wheel must turn
freely.
Drum brake removal

- Remove the rear wheel.
- Hold the lower shoe and slide it out with the upper
one.
For fitting:
- First assembly two shoes and the springs then
place them on the pin and on the cam.
See also
Removing the rear wheel
BRAK SYS - 193

Transmission replacement
- Remove the front handlebar cover.
- Remove the leg shield and the footrest.
- Loosen the brake set screw
- Release the transmission from its retainers to the
engine.
See also
Legshield
Footrest
- Release the transmission from the retainers on

chassis and from the control lever.
- Fit the new transmission, fixing and positioning it
like the one replaced.
- Adjust the drum brake activation point.

Rear brake adjustment nut 5
BRAK SYS - 194

BRAK SYS - 195

INDEX OF TOPICS
CHASSIS CHAS
Typhoon 125 4T (2010-) Chassis
Seat
- Undo the four nuts indicated in the figure and

collect the washers.

Saddle plate fixing nut 10
Driving mirrors
- Lift the rubber cover.

- Loosen the indicated nut, keeping the lower
spacer blocked.
- Undo the mirror from the lower spacer.
- Remove the lower spacer, if necessary.
N.B.
THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK-
WISE.

Mirror fastening spacer 25

- Undo the four screws indicated.
CHAS - 197
Chassis Typhoon 125 4T (2010-)
- Disconnect the connectors of the instrument pan-

el and the odometer cable.
- Remove the handlebar cover together with the
instrument panel and controls.
See also
Instrument panel
- Remove the rear handlebar cover.

See also
CHAS - 198
- Remove the rear-view mirrors and the lower

spacers.
- Undo the front screw.

- Lift the upper edge to release and separate it from
the rear handlebar cover.
- Disconnect the turn indicators connections and
remove the front handlebar cover.
See also
Driving
mirrors
CHAS - 199
Headlight assy.

FRONT TURN INDICATORS

- Undo the three screws indicated.
See also
Legshield
Legshield
- Remove the shield back plate.

- Working from the front wheel housing internal
side, undo the two screws from both sides of the
vehicle.
CHAS - 200
- Undo the indicated screw, beneath the leg shield

lug.
- Move the leg shield forward, opening the lower

ends and detach the headlight bulb connections.
Knee-guard

- Undo the five side screws on the sides of the leg
shield back plate as shown.
CHAS - 201
- Undo the screw in the glove-box and the one un-

der the chassis number lid.
- Before refitting the leg shield back plate, loosen
the footrest fixing screws, so as to fit the two com-
ponents in the best conditions.
N.B.
WHILE REFITTING, PLEASE REMEMBER TO ATTACH THE
GLOVE-BOX OPENING LEVER TO THE KEY-OPERATED
DEVICE.
See also
Front wheel housing

- Remove the front mudguard
- Undo the upper screw.

- Slide the housing off the fork stanchions.
See also
Legshield
Front mudguard
CHAS - 202
Footrest
- Remove the leg shield back plate.

- Undo the indicated screws and remove the pro-
tections.
- Undo the four indicated screws.
See also
Knee-guard
Side fairings
Side fairings
- Remove the rear handles.

- Remove the rear central cover.
CHAS - 203
- Undo side screw from both sides of the vehicle.
- Undo the two screws on the helmet compartment.
- Undo the two upper screws.
- Undo from both sides of the vehicle the screw

placed under the footrest.
CHAS - 204
- Open the front ends of the side fairings to slide

off the indicated upper inserts.
- Disconnect the connections of the turn indicators

and of the rear light unit.
See also
Handles and top side fairings
Rear central cover
License plate holder

- Disconnect the connections of the turn indicators
and of the license plate light.
CHAS - 205
- Undo the rear screw outside the license plate

support.

- Remove the license plate support together with
the turn indicators.
See also
Side fairings
Rear mudguard
- Undo the right-hand side screw.
- Undo the rear screw that fixes also the air filter
box.
CHAS - 206
Helmet bay

- Remove the battery cover and the battery.
- Undo the two screws inside the helmet compart-
ment.
- Disconnect the fuse box and free the helmet

compartment from the cables.
See also
Side fairings
Battery
spoiler
- Remove the footrest.

CHAS - 207
- Undo from both sides of the vehicle the screw

placed under the footrest.
See also
Footrest
Fuel tank
Remove the side fairings and the helmet compart-

ment.
- Detach the pipes from the vacuum-operated
cock.
- Undo the indicated screw on both sides of the

vehicle.
CHAS - 208
- Undo the central screw and loosen the two side

screws on the license plate support frame.
- Disconnect the fuel probe connector and detach

the breather pipe from the filler.

Fuel tank to chassis fixing screws 10
See also
Side fairings
Helmet bay
Rear central cover

- Remove the saddle.
- Undo the four indicated screws and remove the
cover by sliding it upwards so as to detach the
locking tabs on the sides.
See also
CHAS - 209
Seat
Front mudguard
- Operating from both sides of the vehicle, undo

the three indicated screws.
Handles and top side fairings
- Remove the three screws indicated in the figure

and collect the washers.
- Remove the rear handles.

Rear grab handle fixing screw 20.5
Battery
- Undo the three indicated screws and remove the

battery cover.
CHAS - 210
- Disconnect the negative and positive cables.

- Slide off the breather pipe.
CHAS - 211
INDEX OF TOPICS
TIME TIME
Typhoon 125 4T (2010-) Time
Engine
ENGINE
Code Action Duration
1 001001 engine from frame - removal and re-
fitting
TIME - 213
Time Typhoon 125 4T (2010-)
Crankcase
CRANKCASE
1 001133 Engine crankcase - Replacement
2 001153 Crankcase halves gasket - Replace-
ment
3 002031 Rear wheel hub bearings - Replace-
ment
TIME - 214
Crankshaft
CRANKSHAFT
1 001117 Crankshaft - Replacement
2 001099 Flywheel-side oil seal - Replacement
TIME - 215
Cylinder assy.
CYLINDER ASSEMBLY
1 001002 Cylinder-Piston - Replacement
2 001107 Cylinder / piston - Inspection / clean-
ing
TIME - 216
Cylinder head assy.
HEAD ASSEMBLY
1 001045 Valves - Replacement
2 001056 Head gasket - change
3 001126 Head - Replacement
TIME - 217
Rocker arms support assy.
ROCKERS MOUNTING UNIT

1 001044 Camshaft - Replacement
2 001148 Rockers valves - Replacement
3 001049 Valves - adjust
TIME - 218
Cylinder head cover
HEAD COVER
1 001089 Head cover - Replacement
2 001088 Head cover gasket - Replacement
3 001159 Oil vapour recovery tank - Service
4 001093 Spark plug - Replacement
5 001097 Cooling hood - Replacement
6 001091 Head cover sealing ring
7 001074 Oil vapour recovery pipe - Replace-
ment
TIME - 219
Chain tensioner
CHAIN TENSIONER
1 001129 Chain tensioner - Service and Re-
placement
2 001124 By pass lubrication - Replacement
TIME - 220
Oil filter
OIL FILTER
1 001123 Oil filter -Replacement
2 001160 Oil pressure sensor - change
3 003064 Engine oil - change
4 001102 Net oil filter - change / Cleaning
TIME - 221
Flywheel cover
FLYWHEEL COVER
1 001087 Flywheel cover - Replacement
2 001163 Silencer secondary air connection -
Replacement
3 001161 Secondary air filter - Replacement /
Cleaning
4 001174 SAS valve - Replacement
5 001164 Crankcase secondary air connection
- Replacement
TIME - 222
Driven pulley
DRIVEN PULLEY
1 001155 Clutch housing - Replacement
2 001022 Clutch - Replacement
3 001012 Driven pulley - overhaul
4 001110 Driven pulley- Replacement
TIME - 223
Oil pump
OIL PUMP
1 001051 Belt/Timing chain - Change
2 001125 Chain guide pads - Replacement
3 001042 Oil pump - overhaul
4 001112 Oil pump - change
5 001130 Oil sump - change
6 001100 Clutch-side oil seal - Replacement
7 001122 Oil pump chain - Replacement
TIME - 224
Final gear assy.
FINAL REDUCTION GEAR

1 004125 Rear wheel axle - Replacement
2 001156 Gear reduction unit cover - Replace-
ment
3 003065 Gear box oil - Replacement
4 001010 Geared reduction unit - Service
TIME - 225
Driving pulley
DRIVING PULLEY
1 001066 Drive pulley - Removal and refitting
2 001086 Driving half-pulley - Replacement
3 001177 CVT rollers / sliders - Replacement
4 001011 Drive belt - Replacement
TIME - 226
Transmission cover
TRANSMISSION COVER
1 001096 Transmission crankcase cover - Re-
placement
2 001135 Transmission cover bearing - Re-
placement
3 001065 Transmission cover - Removal and
Refit
TIME - 227
Starter motor
STARTER MOTOR
1 001020 Starter motor - Replacement
2 001017 Start-up pinion - Replacement
TIME - 228
Flywheel magneto
Belt cooling duct
TIME - 229
BELT COOLING PIPE

1 001170 Air duct - replacement
2 001132 Transmission air intake pipe - Re-
placement
3 001131 Transmission air intake - Replace-
ment
Carburettor
CARBURETTOR
1 001082 Carburettor heating resistor - Re-
placement
2 001013 Intake manifold - change
3 004122 Air cleaner carburettor fitting - Re-
placement
4 001081 Automatic choke - Replacement
5 001008 Carburettor - Inspection
6 001063 Carburettor - Replacement
TIME - 230
Exhaust pipe
SILENCER
1 001009 Silencer - Replacement
2 001136 Exhaust emissions - Adjustment
3 001095 Silencer heatshield - Replacement
TIME - 231
Air cleaner
AIR CLEANER
1 001014 Air filter - Replacement/Cleaning
2 001015 Air filter box - Replacement
TIME - 232
Frame
CHASSIS
1 004001 Chassis - Replacement
2 004004 Stand - Replacement
3 001053 Stand pin - Replacement
TIME - 233
Legshield spoiler
FRONT SHIELD SPOILER

1 004159 Plates / Stickers - Replacement
2 004149 Shield central cover - Replacement
3 004064 Leg shield, front part - Removal and
refitting
4 004015 Footrest - Removal and Refitting
5 004053 Spoiler - Replacement
TIME - 234
Rear cover
REAR SHIELD
1 004174 Trunk levers - Replacement
2 004065 Legshield, rear part - Removal and
refitting
3 004081 Case lid - Replacement
TIME - 235
Central cover
CENTRAL COVER
1 004059 Spark plug inspection flap - Replace-
ment
2 004106 Helmet compartment band - Re-
placement
3 004085 Fairing (1) - Replacement
4 004105 Right side clamp - Replacement
5 004131 Luggage rack mounting - Replace-
ment
TIME - 236
Underseat compartment
HELMET COMPARTMENT
1 005046 Battery cover - change
2 004016 Helmet compartment - Removal and
Refitting
3 001027 Body / air cleaner union - Replace-
ment
TIME - 237
Plate holder
LICENSE PLATE HOLDER

1 004136 License plate holder mounting - Re-
placement
2 005048 number plate holder - Replacement
TIME - 238
Mudguard
MUDGUARDS
1 004002 Front mudguard - change
2 004009 Rear mudguard - Replacement
TIME - 239
Fuel tank
FUEL TANK
1 004168 Fuel tank cap - Replacement
2 005010 Tank float - Replacement
3 004112 Cock-carburettor hose - Replace-
ment
4 004005 Fuel tank - Replacement
5 004007 Fuel valve - Replacement
6 004109 Fuel tank breather - change
TIME - 240
Rear shock-absorber
REAR SHOCK ABSORBER

1 003007 Rear shock absorber - Removal and
Refitting
TIME - 241
Steering column bearings
STEERING BEARING
1 003002 Steering bearing - Replacement
2 003073 Steering clearance - Adjustment
TIME - 242
Handlebar covers
HANDLEBAR COVERS
1 004019 Handlebar rear section - Replace-
ment
2 004018 Handlebar front section - Replace-
ment
3 005078 Odometer glass - Replacement
4 005076 Clock / Cell - Replacement
5 005014 Odometer - Replacement
6 005038 Instrument panel warning light bulbs
- Replacement
TIME - 243
Handlebar components
HANDLEBAR COMPONENTS
1 004066 Driving mirror - Replacement
2 002037 Brake or clutch lever - Replacement
3 002071 Left hand grip - Replacement
4 003001 Handlebar - Removal and refitting
5 005017 Stop switch - Replacement
6 002024 Front brake pump - Removal and Re-
fitting
7 003061 Accelerator transmission - adjust
8 002060 Complete throttle control - Replace-
ment
9 004162 Mirror mounting and/or brake pump
fitting U-bolt - Replacement
10 002059 Right hand grip - Replacement
11 002063 Throttle control transmission - Re-
placement
TIME - 244
Swing-arm
SWINGING ARM
1 001072 Swinging arm connecting the engine
to the frame - Replacement
2 003080 Swinging arm on frame - Replace-
ment
TIME - 245
Brake hoses
BRAKE HOSES
1 002007 Front brake shoes/pads - Remov.
and Refitt
2 002039 Front brake calliper - Remov. and
Refitt
3 002021 Front brake hose - Remov. and Re-
fitt.
4 002047 Front brake fluid and system bleed -
Repl
TIME - 246
Seat
SADDLE
1 004003 Saddle - Replacement
2 004068 Passenger handgrip - Replacement
TIME - 247
Turn signal lights
INDICATOR LIGHTS
1 005002 Front headlamp - Replacement
2 005012 Front turn indicator - Replacement
3 005067 Front turn indicator bulb - Replace-
ment
4 005008 Headlight bulbs - Replacement
5 005005 Taillight - change
6 005066 Rear light bulbs - Replacement
7 005022 Rear turning indicators - Replace-
ment
8 005068 Rear turning indicator bulb - Re-
placement
9 005131 Licence plate light support - Replace-
ment
10 005031 Licence plate light - Replacement
11 005032 licence plate light glass - Replace-
ment
TIME - 248
Front wheel
FRONT WHEEL
1 003038 Front wheel axle - Remov. and Refitt.
2 002011 Odometer tone wheel - Replacement
3 003040 Front wheel bearings - Replacement
4 003047 Front tyre - Replacement
5 003037 Front wheel rim - Removal and Re-
fitting
6 004123 Front wheel - Replacement
7 002041 Brake disc - Replacement
Tone wheel or drive greasing

Please note that the following code has been in-
troduced:
900001 - Tone wheel or drive greasing -15'.
Please do not use codes 002011 (drive replace-
ment) and 005089 (tone wheel replacement) in-
correctly if the indicated components are noisy.
The recommended grease is TUTELA MRM 2
(soap-based lithium grease with molybdenum di-
sulphide).
The area to be greased is indicated below with an
arrow (1 - Drive, 2 - Tone wheel)
TIME - 249
Rear wheel
REAR WHEEL
1 002002 Rear brake pads/shoes - Repl.
2 004126 Rear wheel tyre - Replacement
3 001016 Rear wheel - Replacement
4 001071 Rear wheel rim - Removal and Refit-
ting
TIME - 250
Electric devices
ELECTRICAL DEVICES
1 001023 Control unit - Replacement
2 005035 Headlight solenoid - Replacement
3 005001 Electrical system - Replacement
4 001094 Spark plug cap - Replacement
5 001069 HV coil - Replacement
6 005052 Fuse - Replacement
7 005025 Battery fuse holder - Change
8 005009 Voltage regulator - Replacement
9 005011 Start-up solenoid - Replacement
10 005007 Battery - change
11 005114 Electrical system - Overhaul
Electronic controls
ELECTRIC CONTROLS
1 005039 Lights switch - Replacement
2 005006 Light or turning indicator switch - Re-
placement
3 005040 Horn button - Replacement
4 005003 Horn - Replacement
5 005041 Starter button - Replacement
6 005016 Key switch - Replacement
7 004096 Lock series - Replacement
8 005072 Immobilizer antenna - Replacement
TIME - 251
Front suspension
FRONT SUSPENSION
1 003010 Front suspension - Service
2 003048 Fork oil seal - Replacement
3 003076 Fork sleeve - Replacement
4 003079 Fork stem - Replacement
5 003051 Complete fork - Replacement
6 003069 Front fork oil - Replacement
TIME - 252
A
Air filter: 36
B
Battery: 49, 65, 72, 79, 80, 207, 210
Brake: 173, 187, 189, 190, 192, 193, 246
Bulbs:
C
Carburettor: 15, 148, 154, 230
Checks: 70
E
Electric: 251
Engine oil: 37
F
Fuel: 48, 147, 208, 240
Fuses: 78
H
Headlight: 42, 200
Horn: 76
Hub oil: 34
I
Identification: 12
Instrument panel: 198
M
Maintenance: 11, 31
Mirrors: 197, 199
O
Oil filter: 37, 38, 221
R
Recommended products: 31
S
Saddle:
Shock absorbers: 183
Spark plug: 33, 70
Start-up:
Suspension: 50, 252
T
Tank: 208, 240
Technical Data: 11
Transmission: 13, 48, 90, 102, 113, 227
Turn indicators: 69
Tyres: 14
V
Vehicle: 12, 85

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SERVICE STATION MANUAL

Typhoon 125 4T (2010-)

Typhoon 125 4T (2010-)

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

Tightening torques inspection

Rear shock absorber lower fixing

Front wheel axle nut

Wheel hub nut

Swinging arm - frame pin

Engine - swinging arm pin

Engine arm pin - Chassis arm

Handlebar lock nut

Lower steering ring nut

Upper steering ring nut

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

- Minimum holding (turning the handlebar)

Dimensions and mass

WEIGHTS AND DIMENSIONS

Frame and suspensions

CHASSIS AND SUSPENSION

Wheels and tyres

WHEELS AND TYRES

In order to reduce polluting emissions, the vehicle

The filter sponge should be cleaned with water and

CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE

HEAD AND CYLINDER

CRANKCASE AND CRANKSHAFT

FUEL TANK UNIT

Cylinder - piston assy.

PISTON TO CAST IRON CYLINDER COUPLING (125)

Name Initials Cylinder Piston Play on fitting

SEALING RINGS (125)

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS

Name Description Dimensions Initials Quantity

Slot packing system

001467Y009 Bell for OD 42-mm bearings

001467Y013 Calliper to extract ø 15-mm bearings

002465Y Calliper for circlips

005095Y Engine support

006029Y Punch for fitting steering bearing on the

Stores code Description

020004Y Punch for removing steering bearings

020055Y Wrench for steering tube ring nut

020074Y Support base for checking crankshaft

020150Y Air heater mounting

020151Y Air heater

020193Y Oil pressure gauge

Stores code Description

020263Y Driven pulley assembly sheath

020271Y Tool for removing-fitting silent bloc

020306Y Punch valve seal rings fitting

020329Y Mity-Vac vacuum pump

020330Y Stroboscopic light to check timing

Stores code Description

020332Y Digital rpm indicator

020334Y Multiple battery charger

020335Y Magnetic mounting for dial gauge

020357Y 32 x 35-mm Adaptor

Stores code Description

020363Y 20-mm guide