BOULEVARD 50 2T

BOULEVARD 50 2T
WORKSHOP MANUAL
BOULEVARD 50 2T
INDEX OF TOPICS
CHARACTERISTICS
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
TROUBLESHOOTING
TROUBL
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
ENG
SUSPENSIONS
SUSP
BRAKING SYSTEM
CHASSIS
PRE-DELIVERY
TIME
BRAK SYS
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original DERBI 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, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. 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 electric connections have been done properly, particularly the ground and battery connections.
CHAR - 7
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION
Specification
Frame prefix
Engine prefix
Desc./Quantity
ZAPM44100 ÷ 1001
VTHBR1A1 xxxxxxxxx
Dimensions and mass
DIMENSIONS AND MASS
Specification
Dry weight
Length
Maximum height
Seat height
Width
Wheelbase
CHAR - 8
Desc./Quantity
97 Kg
1,880
1150 mm
785
735
1,340
Characteristics
Engine
ENGINE
Specification
Engine type
Bore x stroke
Cubic capacity
Compression ratio
Carburettor
CO adjustment
Engine idle speed
Air filter
Starting system
Lubrication
Fuel supply
Cooling system
Desc./Quantity
Two-stroke, single cylinder Piaggio Hi-PER2
40 X 39.3 mm
49.40 cc
10,3 :1
DELL'ORTO PHVA 17.5
3.5% ± 0.5
1800 to 2000 r.p.m.
Sponge, soaked in a mixture (50% SELENIA Air Filter Oil and
50% unleaded petrol).
electric starter/kick-starter
With blend and variable oil variable according to the engine
revolutions and the throttle valve opening by means of a pump
controlled by the driving shaft with toothed belt.
Gravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor.
forced coolant circulation system
CHAR - 9
Characteristics
Transmission
TRANSMISSION
Specification
Transmission
Desc./Quantity
With automatic expandable pulley variator, torque server, Vbelt, automatic clutch, gear reduction unit.
Capacities
CAPACITIES
Specification
Rear hub oil
oil mixer tank
Fuel tank capacity
Desc./Quantity
Quantity: approx. 85 cc
Plastic, capacity ~ 1.2 l
approx. 7.2 litres (of which 1.5 l is reserve)
Electrical system
ELECTRICAL SYSTEM
Specification
Type of ignition
Ignition advance (before TDC)
Recommended spark plug
Battery
Main fuse
Generator
Desc./Quantity
Capacitive discharge type electronic ignition, with incorporated
high voltage coil
Fixed 17° ± 1
CHAMPION RN2C
12V-4Ah
7.5 A
In alternate current with three output sections
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Type of chassis
Front suspension
Rear suspension
Desc./Quantity
Welded tubular steel chassis with stamped sheet reinforcements.
Telescopic mechanical fork, 76mm travel.
Single hydraulic shock absorber, 72.5-mm travel
Brakes
FRENI
Specification
Front brake
Rear brake
Desc./Quantity
Disc brake (Ø 200 mm) with hydraulic control (lever on the right
end of the handlebar) and floating calliper.
drum brake (Ø 140 mm) with mechanical linkage.(l.h. brake
lever).
Wheels and tyres
WHEELS AND TYRES
Specification
Front wheel rim
Front tyre
CHAR - 10
Desc./Quantity
Die-cast aluminium alloy 3.50 x 12"
Tubeless, 120/70-12"
Characteristics
Specification
Rear wheel rim
Rear tyre
Front tyre pressure
Rear tyre pressure
Rear wheel pressure (rider and passenger):
Desc./Quantity
Die-cast aluminium alloy: 3.00"x12"
Tubeless, 120/70 - 12"
1.8 bar
2 bar
2.3 bar
Secondary air
Follow these steps to clean the sponge filters of
the secondary air system:
1) Remove the snap-on plastic cover (1) on the
transmission cover using a small screwdriver as a
lever on the retaining tongues in order to insert one
of the three slots found on that cap.
2) Wash the polyurethane sponge with water and
soap, dry all components with compressed air and
refit to place. Refit the intake cap respecting the
angle reference.
3) Undo the two fixing screws (2) on the aluminium
cover of the secondary air housing in order to
reach the polyurethane sponge inside that housing; clean as indicated in point 2) and refit all
elements after checking the steel tab is not deformed and/or does not guarantee correct tightness at its fitting; replace if necessary.
N.B.
UPON REFITTING, MAKE SURE TO CORRECTLY FIT THE
TAB IN ITS FITTING ON THE TWO PLASTIC AND ALUMINIUM COVERS.
CAUTION
WHILE CARRYING OUT OPERATION 3), ALWAYS CHECK
THE TWO RUBBER COUPLINGS (3) ON ONE END OF THE
SECONDARY AIR PIPE FOR CORRECT TIGHTNESS AND
CONTINUITY; IF NECESSARY, REPLACE THEM AND USE
NEW CLAMPS TO FIX THEM.
Carburettor
50cc Version
CHAR - 11
Characteristics
Dell'Orto
DELLORTO CARBURETTOR
Specification
Type
Diffuser diameter
Regulation reference number
Maximum nozzle:
Maximum air nozzle (on the body):
Tapered pin stamped code:
Pin position (notches from above):
Diffuser:
Minimum nozzle:
Minimum air nozzle (on the body):
Initial minimum mix screw opening:
Starter jet
Starter air nozzle (on the body):
Stroke of starter pin:
Gasoline inlet hole
Desc./Quantity
PHVA 17.5 RD
Ø 17.5
8423
53
Ø 1.5
A22
1
209 HA
32
Free
1 1/2
50
Ø 1.5
11 mm
Ø 1.5
Tightening Torques
FRONT BRAKE
Name
Brake fluid pump - hose fitting
Brake fluid pipe-calliper fitting
Calliper tightening screw
Disc tightening screw
Oil bleed screw
Torque in Nm
16 ÷20 Nm
19 ÷ 24
24 ÷ 27
8 ÷ 10
7 ÷ 10
FRONT SUSPENSION
Name
Lower fork fixing screw
Front wheel axle nut
Torque in Nm
15 ÷ 20
45 - 50
STEERING ASSEMBLY
Name
Upper steering ring nut
Steering lower ring nut
Handlebar fixing screw
Torque in Nm
35 ÷ 40
8 ÷ 10
50 ÷ 55
ENGINE ASSEMBLY
Name
Clutch bell nut (**)
Clutch lock ring nut
Nut locking driving pulley on crankshaft (**)
Start-up lever screw
Flywheel nut (**)
Flywheel fan screws
Half-crank case joint bolts
Bolts holding exhaust pipe to the crankcase
Screws holding the filter box to the crank case
Head nuts
Starter screws
Ignition spark plug
Hub oil drainage cap
Oil hub level dipstick
Rear hub cap screws
Transmission cover screws
Inlet manifold screws
CHAR - 12
Torque in Nm
40 ÷ 44
55 ÷ 60
40 ÷ 44 Nm
12 ÷ 13
40 ÷ 44
3÷4
12 ÷ 13
22 ÷ 24
4÷5
10 ÷ 11
12 ÷ 13
25 ÷ 30
3÷5
Manual
12 ÷ 13
12 ÷ 13
8÷9
Characteristics
Name
Flywheel hood fixing screws
Cylinder hood fixing screws
Stator clamping screws
Pick-Up clamping screw
Mixer clamping screws
Screw fixing brake lever to the journal on the engine
Torque in Nm
1÷2
3.5 ÷ 5
3÷4
4÷5
3÷4
12 ÷ 13
CHASSIS
Name
Swinging arm - engine pin*
Frame/swing-arm bolt (*)
Shock absorber - chassis nut (*)
shock absorber - engine pin (*)
Rear wheel axle (*)
Centre-stand mounting bracket bolt
Centre-stand mounting bracket screw
Side stand fixing screw
Side stand bracket fixing screw
Torque in Nm
33 ÷ 41
64÷72
20 to 25 Nm
33 to 41 N·m
104÷126 N·m
25÷30 N·m
20÷25 N·m
12 ÷ 20
15 ÷ 20
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER
Name
Standard coupling
Standard coupling
Standard coupling
Standard coupling
coupling 1st oversize
coupling 1st oversize
coupling 1st oversize
coupling 1st oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Initials
M
N
O
P
M1
N1
O1
P1
M2
N2
O2
P2
Cylinder
40.005 - 40.012
40.012 - 40.019
40.019 - 40.026
40.026 - 40.033
40.205 - 40.212
40.212 - 40.219
40.219 - 40.226
40.226 - 40.233
40.405 - 40.412
40.412 - 40.419
40.419 - 40.426
40.426 - 40.433
Piston
39.943 - 39.95
39.95 - 39.957
39.957 - 39.964
39.964 - 39.971
40.143 - 40.15
40.15 - 40.157
40.157 - 40.164
40.164 - 40.171
40.343 - 40.35
40.35 - 40.357
40.357 - 40.364
40.364 - 40.371
Play on fitting
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
0.055 - 0.069
CHAR - 13
Characteristics
Piston rings
SEALING RING
Name
Compression ring
Compression ring 1st
oversize
Compression ring 2nd
Oversize
Description
Dimensions
40
40.2
Initials
A
A
Quantity
0.10 to 0.25
0.10 to 0.25
40.4
A
0.10 to 0.25
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD
Name
Connecting rod
Description
Dimensions
11.750-0.05
Initials
A
shoulder washer
0.5 ± 0.03
G
Half-shaft, transmission
side
13.75+0.040
C
Flywheel-side half-shaft
13.75+0.040
D
Lining between the
shoulders
40.64
H
Cage
11.800-0.35
B
Slot packing system
This type of engines foresees the use of one size of basic gaskets.
CHAR - 14
Quantity
clearance E = 0.25 to
0.50
clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
clearance E = 0.25 to
0.50 - clearance F =
0.20 to 0.75
clearance F = 0.20 to
0.75
Characteristics
For 25 km/h engine type versions, use 2 gaskets between cylinder and crankcase.
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP ROTRA 80W-90
AGIP CITY HI TEC 4T
AGIP FILTER OIL
AGIP CITY TEC 2T
AGIP BRAKE 4
MONTBLANC MOLYBDENUM
GREASE
AGIP GREASE PV2
AGIP GREASE SM 2
AGIP GP 330
Description
Rear hub oil
Specifications
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Oil to lubricate flexible transmissions
Oil for 2-stroke engines: SAE 5W-40, API
(brake, throttle control and mixer, odomSL, ACEA A3, JASO MA
eter)
Oil for air filter sponge
Mineral oil with specific additives for increased adhesiveness
Mixer oil
synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
Brake fluid
FMVSS DOT 4 Synthetic fluid
Grease for driven pulley shaft adjusting
Grease with Molybdenum disulphide
ring and movable driven pulley housing
Grease for steering bearings, pin seats White anhydrous-calcium based grease
and swinging arm
to protect roller bearings; temperature
range between -20 C and +120 C; with
NLGI 2; ISO-L-XBCIB2.
Grease for odometer transmission gear Lithium grease with NLGI 2 molybdenum
case
disulphide; ISO-L-XBCHB2, DIN
KF2K-20
Grease for brake control levers, throttle,
White calcium complex soap-based
stand
spray grease with NLGI 2; ISO-L-XBCIB2
CHAR - 15
INDEX OF TOPICS
TOOLING
TOOL
Tooling
TOOLS
Stores code
001330Y
Description
Tool for fitting steering seats
001467Y006
Pliers to extract 20 mm bearings
001467Y007
Driver for OD 54 mm bearing
001467Y009
Driver for OD 42-mm bearings
001467Y013
Pliers to extract ø 15-mm bearings
001467Y014
Pliers to extract ø 15-mm bearings
TOOL - 17
Tooling
TOOL - 18
Stores code
001467Y017
Description
Bell for bearings, OD 39 mm
001467Y021
Extraction pliers for ø 11 mm bearings
002465Y
Pliers for circlips
006029Y
Punch for fitting fifth wheel seat on steering tube
020004Y
Punch for removing fifth wheels from
headstock
020055Y
Wrench for steering tube ring nut
020150Y
Air heater mounting
Tooling
Stores code
020151Y
Description
Air heater
020162Y
Flywheel extractor
020163Y
Crankcase splitting plate
020164Y
Driven pulley assembly sheath
020165Y
Start-up crown lock
020166Y
Pin lock fitting tool
TOOL - 19
Tooling
TOOL - 20
Stores code
020261Y
Description
Starter spring fitting
020262Y
Crankcase splitting plate
020265Y
Bearing fitting base
020325Y
Pliers for brake-shoe springs
020329Y
Mity-Vac vacuum-operated pump
020330Y
Stroboscopic light to check timing
Tooling
Stores code
020331Y
Description
Digital multimeter
020332Y
Digital rpm indicator
020333Y
Single battery charger
020334Y
Multiple battery charger
TOOL - 21
Tooling
TOOL - 22
Stores code
020335Y
Description
Magnetic mounting for dial gauge
020350Y
Electrical system check instrument
020357Y
020359Y
32x35-mm Adaptor
42x47-mm Adaptor
020376Y
Adaptor handle
020412Y
15-mm guide
Tooling
Stores code
020456Y
Description
Ø 24 mm adaptor
020483Y
30-mm guide
020565Y
Flywheel lock calliper spanner
494929Y
Exhaust fumes analyser
TOOL - 23
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change
AFTER 1000 KM
50'
Action
Hub oil - change
Oil mixer/throttle linkage - adjustment
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
AFTER 5000 KM, 25000 KM, 35000 KM AND 55000 KM
40'
Action
Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - clean
Oil mixer/throttle linkage - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
AFTER 10000 KM, 50000 KM
95'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Variable speed rollers - replacement
Odometer gear - greasing
Driving belt - checking
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See regulations in the «Adjusting the idle speed» section
AFTER 15000 KM AND 45000 KM
65'
MAIN - 25
Maintenance
Action
Hub oil level - check
Spark plug/electrode gap - replacement
Air filter - cleaning
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test
(**) See regulations in the «Secondary air system» section
AFTER 20000 KM AND 40000 KM
110'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Cylinder cooling system - check/cleaning
Oil mixer/throttle linkage - adjustment
Driving belt - checking
Variable speed rollers - replacement
Mixer belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See section «Adjusting the idle speed»
AFTER 30000 KM
130'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Variable speed rollers - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Flexible brake tubes - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test
MAIN - 26
Maintenance
(*) See regulations in the «Adjusting the idle speed» section
(**) See regulations in the «Secondary air system» section
AFTER 60000 KM
150'
Action
Hub oil - change
Spark plug/electrode gap - replacement
Air filter - clean
Idling speed (*) - adjustment
Cylinder cooling system - check/cleaning
Oil mixer/throttle linkage - adjustment
Driving belt - replacement
Variable speed rollers - replacement
Mixer belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Flexible brake tubes - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
SAS box (sponge) (**) - cleaning
Vehicle and brake test - road test
(*) See regulations in the «Adjusting the idle speed» section
(**) See regulations in the «Secondary air system» section
Carburettor
- Disassemble the carburettor in its parts, wash all
of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condition.
-The throttle valve should move freely in the
chamber. Replace valve in case of wear due to
excessive clearance.
- If there are wear marks in the chamber causing
inadequate tightness or a free valve slide (even if
it is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE
GASKETS TO AVOID PETROL LEAKS
MAIN - 27
Maintenance
1. Automatic starter - 2. Idle air set screw - 3. Idle speed set screw - 4. Throttle valve spring - 5. Throttle
valve tapered pin - 6. Throttle valve - 7. Carburettor body - 8. Pin - 9. Min. jet - 10. Float - 11. Max. jet
- 12. Float chamber
Checking the spark advance
-Check to be made at over 4000 rpm with stroboscopic gun. The advanced ignition measured must
be 17° before the TDC.
- This value is correct when the reference mark on
the flywheel hood is aligned with the reference
mark on the cooling fan and the phase shifter on
the stroboscopic gun is set on 17°.
N.B.
IN CASE OF MALFUNCTION, CARRY OUT THE CHECKS
PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
BEFORE CARRYING OUT THE ABOVE CHECKS, CHECK
THE CORRECT KEYING OF THE FLYWHEEL ON THE
CRANKSHAFT.
Specific tooling
020330Y Stroboscopic light to check timing
Spark plug
Place the vehicle on its central stand
- Remove the central cover, indicated in the figure,
by undoing the 2 fixing screws;
- Disconnect spark plug HV wire hood;
-Undo the spark plug using the socket wrench;
-Examine the condition of the spark plug, check
that the insulating material is whole and measure
the distance between the electrodes using a thickness 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;
MAIN - 28
Maintenance
- 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;
-Put the hood on the sparking plug as far as it will
go;
- Refit the central flap.
CAUTION
THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD. THE SPARK PLUG MUST BE REPLACED
EVERY 5000 KM. USE OF STARTERS NOT CONFORMING
OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Recommended spark plug
CHAMPION RN2C
Electric characteristic
Electrode gap
0.6 to 0.7 mm.
Locking torques (N*m)
Spark plug 25 - 30 Nm
Hub oil
Check
Do the following to check the correct level:
1) Stand the vehicle on the centre-stand on flat
ground;
2) Remove the dipstick «A», and dry it with a clean
cloth. Reinsert it, screwing it in all the way;
3) Remove the stick and check that the oil level is
slightly over the second notch starting from the
lower end;
4) Screw the dipstick back in, checking that it is
locked in place.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
MAIN - 29
Maintenance
Replacement
- Remove the oil filler cap «A».
- Loosen the oil draining cap «B» and let the oil
completely drain the tank.
- Tighten the draining cap and refill the hub with oil
(approx. 75 cc).
Air filter
-Remove the cap of the purifier, unscrewing the six
clamping screws and removing the filter.
Cleaning:
-Wash with water and neutral soap.
- Dry with a clean cloth and short blasts of compressed air.
-Saturate with a 50% mixture of gasoline and oil.
-Drip dry the filter and then squeeze it between the
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.
Recommended products
AGIP FILTER OIL Oil for air filter sponge
Mineral oil with specific additives for increased adhesiveness
MAIN - 30
Maintenance
Checking the ignition timing
- Adjust the control cables:
Mix cable: see procedure indicated in "Mixer timing".
Throttle cable: adjust the set screw on the carburettor in such a way that the sheath has no backlash.
Splitter control cable: adjust set screw on the throttle control to the handlebar in such a way that there
is no backlash on the throttle control.
Adjust all transmissions in such a way that their
sheathings show no sign of backlash.
Mixer Timing
- Using the transmission set screw on the crankcase, with throttle control untwisted, adjust the
reference mark on the rotating plate so that it is
lined up with the reference mark on the mixer
body, as shown in the figure.
While doing this, the engine must be fuelled with a
2 % oil mixture (0.5 litre minimum if the reservoir
is empty).
CAUTION
IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN
THE RESERVOIR BLEED THE MIXER AS FOLLOWS: REFILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED
TO THE VEHICLE AND THE ENGINE IS OFF, UNDO THE
MIXER PIPE FROM THE CARBURETTOR AND LOOSEN
THE BLEED SCREWS (SEE THE ARROW IN THE FIGURE)
UNTIL THE OIL BEGINS TO FLOW OUT. TIGHTEN THE
SCREWS, START UP THE ENGINE AND WAIT FOR OIL TO
FLOW OUT OF THE TUBE. RECONNECT THE DELIVERY
PIPE TO THE CARBURETTOR AND FIX IT IN PLACE WITH
THE RELEVANT METAL CLIP.
Recommended products
AGIP CITY TEC 2T Mixer oil
synthetic oil for 2-stroke engines: JASO FC, ISOL-EGD
Braking system
MAIN - 31
Maintenance
Level check
Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars perfectly horizontal;
- Check the level of liquid with the related warning
light «A».
A certain lowering of the level is caused by wear
on the pads.
Top-up
Proceed as follows:
- Remove the tank cap by loosening the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maximum level.
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR
EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL
CONTACT, WASH WITH WATER.
CAUTION
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE
SURE THAT IT DOES NOT COME INTO CONTACT WITH
THE PAINTWORK.
CAUTION
THE BRAKE FLUID IS HYGROSCOPIC, IN OTHER WORDS,
IT ABSORBS MOISTURE FROM THE SURROUNDING AIR.
IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID
EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY
USED CONTAINERS.
UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID
MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO
THE CHANGING OF BRAKE FLUID AND THE BLEEDING
OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
MAIN - 32
Maintenance
Headlight adjustment
Proceed as follows:
1. Place the vehicle, in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10-m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the scooter is perpendicular to the screen;
2. Turn on the headlight and check that the borderline of the projected light beam on the screen
is not higher than 9/10 or lower than 7/10 of the
distance from the ground to the centre of vehicle
headlamp;
3. If otherwise, adjust the right headlight with screw
«A».
N.B.
THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
CO check
In the event that the exhaust on the vehicle being
tested does not have an exhaust gases collection
port, proceed as follows:
- Remove the R.H. side fairing
- Remove the secondary air box cover with the
aluminium cap by acting upon the clamp shown in
the figure.
Attach the exhaust gas collection tube to the secondary air rubber manifold. Such joint must be
sealed in order to guarantee accurate CO readings.
- Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1%
MAIN - 33
Maintenance
- If the parameters found do not agree with the above figures, act upon the idle adjusting screw. Otherwise, check the automatic choke device
Specific tooling
020320Y Exhaust gases analyser
020332Y Digital rpm indicator
The check must be carried out after having carefully cleaned all carburettor components, with the
air filter clean, and the spark plug in good conditions.
- Remove the R.H. side fairing
- Warn-up the engine by riding the vehicle on the
road for at least 10 minutes
- Shut down the engine
- Remove the 2 secondary air box screws shown
in the figure
− Place a plastic sheet between the one-way valve
and the aluminium outlet as shown in the figure
− Ensure the one-way valve packing properly
seals the aluminium outlet fitting.
− Refit the aluminium outlet onto the SAS box as
shown in the picture.
MAIN - 34
Maintenance
- Attach the special tool and move the joints as
shown in the figure.
- Start the engine, adjust the idle speed to 1,700 ±
100 rpm and check the CO value is equal 3.5 ± 1%
- If the parameters found do not agree with the
above figures, act upon the idle adjusting screw.
Otherwise, check the automatic choke device.
Specific tooling
020320Y Exhaust gases analyser
020332Y Digital rpm indicator
020625Y Kit for sampling gas from the exhaust
manifold
SAS filters inspection and cleaning
After removing the spark plug cap, remove the
RHS fairing, by loosening the three fixing screws
«B» shown in the figure.
Remove the SAS aluminium cover fixing screws
«A». Detach the metal hose from its rubber housing on the cover, without detaching it from the
cover/bellow. Hence remove plate and plastic cover, extract the sponge and wash it with soap. Dry
with compressed air before refitting, ensuring to
correctly positioning the plate in the housing machined on the plastic and aluminium covers.
Whenever removing the part, always replace the
O-ring located on the special housing on the cover.
MAIN - 35
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
This section makes it possible to find the solutions to use in troubleshooting.
For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Poor performance
POOR PERFORMANCE
Possible Cause
Fuel nozzles or cock clogged or dirty
Excess of encrustations in the combustion chamber
Lack of compression wear of the piston rings or cylinder
Exhaust pipe clogged due to excessive encrustations
Air filter blocked or dirty
Starter inefficient (stays on)
Clutch slipping
Defective mobile pulley sliding
Driving belt worn
Carburettor nozzles clogged
Fuel filter on vacuum operated cock blocked
Roller wear; Presence of oil; Dirt
Operation
Dismantle, wash with solvent and dry with compressed air
Remove the encrustations
Check the worn parts and replace them
Replace the exhaust pipe and check the carburation and mixer
timer
Clean according to the procedure
Check the mechanical sliding, continuity of the circuit, the presence of power and electrical wiring
Check the centrifugal brake shoe assembly and /or clutch bell
and replace if necessary
Check the parts, change the faulty parts and lubricate the driven pulley using only Montblanc-Molibdenum Grease (dis.
498345) grease
Replace
Dismantle, wash with solvent and dry with compressed air
Clean the cock filter
Check the cap with filter is fitted to the transmission cover;
clean the speed variator, replace the rollers if worn out
Rear wheel spins at idle
REAR WHEEL
Possible Cause
Idling rpm too high
Clutch fault
Air filter housing not sealed
Operation
Check the idling speed and, if necessary, adjust the C.O.
Check the spring/friction mass and the clutch bell
Correctly refit the filter housing and replace it if it is damaged
Starting difficulties
DIFFICULTY STARTING
Possible Cause
Carburettor nozzles clogged or dirty
Faulty fuel cock
Starter inefficient
Defective spark plug or with incorrect electrode gap
Battery flat
- Engine flooded.
Operation
Dismantle, wash with solvent and dry with compressed air
Check that, at ignition and with throttle untwisted, no petrol
flows out the delivery pipe; otherwise, replace the vacuum-operated cock
Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Check and if necessary replace the spark plug and the electrode gap
Check the state of the battery. If it shows signs of sulphation
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
Start the vehicle keeping the throttle fully open alternately making the engine run for approx. five seconds and stopping for
other five seconds. If however it does not start, remove the
spark plug, the engine over with the throttle open being careful
TROUBL - 37
Troubleshooting
Possible Cause
Altered fuel characteristics
Faulty spark plug
Intake joint cracked or with a bad seal
Purifier-carburettor fitting damaged
Operation
to keep the cap in contact with the spark plug and the spark
plug grounded but away from its hole. Refit a dry spark plug
and start the vehicle.
Drain off the fuel no longer up to standard; then, refill
Remove the encrustation, restore the plug gap or replace being
sure to use the types of spark plug recommended at all times.
Bear in mind that many problems engines have, derive from
the use of the wrong spark plug
Replace intake joint and check for correct sealing on the head
Replace
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause
Excess of encrustations in the combustion chamber
Operation
Remove the encrustations
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE
Possible Cause
Maximum nozzle dirty - lean mixture
Dirty carburettor
Water in the carburettor
Air filter dirty
Defective floating valve
Tank breather hole obstructed
Operation
Wash the nozzle with solvent and dry with compressed air
Wash the carburettor with solvent and dry with compressed air
Empty the tank through the appropriate bleed nipple.
Clean or replace
Check the proper sliding of the float and the functioning of the
valve
Restore the proper reservoir aeration
Engine tends to cut-off at idle
ENGINE STOP IDLING
Possible Cause
Minimum nozzle dirty
Starter that stays open
Reed valve does not close
Wrong idling adjustment
Spark plug defective or faulty
Operation
Wash the nozzle with solvent and dry with compressed air
Check: electric wiring, circuit continuity, mechanical sliding and
power supply
Check / replace the reed pack
Correctly adjust the engine idling and check the level of the
C.O.
Replace the spark plug with one with the specified degree and
check the plug gap
Excessive exhaust noise
INCREASED NOISINESS
Possible Cause
Secondary metal air pipe deteriorated
Operation
Check there are no leaks on the hoses on the crankcase and
the housing, check that there is a cap with filter and it is correctly
fitted to the transmission cover
Good condition of the missing secondary air circuit components Check the individual components and the piping, check the
precision of the fitting. Replace the damaged components
TROUBL - 38
Troubleshooting
High fuel consumption
HIGH FUEL CONSUMPTION
Possible Cause
Air filter blocked or dirty.
Starter inefficient
Operation
Clean according to the procedure
Check: electric wiring, circuit continuity, mechanical sliding and
power supply
SAS malfunctions
SLACKENING OF THE RUBBER JOINT OF THE SECONDARY AIR PIPE ON THE MUFFLER
Possible Cause
Secondary air reed blocking
Secondary air filter clogging
Blockage of the secondary air fitting on the muffler
Operation
Replace
Clean the filter and the housing
Remove the encrustations from the joint being careful not to let
the debris fall into the muffler
Transmission and brakes
Clutch grabbing or performing inadequately
CLUTCH BRAKES
Possible Cause
Slippage or irregular functioning
Operation
Check that the masses open and return normally
Check that there is no grease on the masses
Check that the clutch masses' contact surface with the clutch
bell is mainly in the middle with characteristics equivalent on
the three masses
Check that the clutch bell is not scored or worn abnormally
Never operate the engine without the clutch bell
Check the cap with filter is fitted to the transmission cover
Insufficient braking
BRAKING SYSTEM MALFUNCTION
Possible Cause
Poor braking
Air bubbles inside the hydraulic braking system
Fluid leakage in hydraulic braking system
The brake fluid has lost its properties
Defective sliding of the cables in their sheathes
Brake noise
Operation
The rear (drum type) brake is adjusted by regulating the special
adjustment (on the wheel) bearing in mind that, with the control
levers in the rest position, the wheels must turn freely.
The braking action should begin when the brake levers are
pressed by about a third.
Check the brake pad wear.
If it is not possible to remove any problems by simply adjusting
the transmissions, check the brake pads and front brake disc,
the brake shoes and the rear drum. If you encounter excessive
wear or scoring, make the necessary replacements.
Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Elastic fittings, piston seals or brake pump breakdown, replace
Replace the front brake fluid and top up to the correct level in
the pump
Lubricate or substitute
Check the wear of the brake pads and/or shoes
TROUBL - 39
Troubleshooting
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Defective piston sliding
Brake disc or drum deformed
Operation
Check calliper and replace any damaged part.
Using a dial gauge, check the planarity of the disk with the
wheel correctly fitted or the concentricity of the rear drum.
Electrical system
Battery
BATTERY
Possible Cause
Battery
Operation
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, keeping 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.
Steering and suspensions
Rear wheel
REAR WHEEL
Possible Cause
Idle speed set too high
Faulty clutch
Operation
Adjust idle speed. Adjust C.O. if necessary
Check springs / frictional weights and clutch housing.
Heavy steering
STEERING HARDENING
Possible Cause
Torque not conforming
Operation
Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
EXCESSIVE STEERING CLEARANCE
TROUBL - 40
Operation
Check the tightening of the top and bottom ring nuts.
If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball
bearings rotate: replace if they are recessed.
Troubleshooting
Noisy suspension
NOISY SUSPENSION
Possible Cause
NOISY SUSPENSION
Operation
If the front suspension is noisy, check: the efficiency of the front
shock absorbers; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers and the movement
bushings.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION
Possible Cause
Oil leakage from suspension
Operation
Service the pumping members and check the sleeves and
sealing rings are in good conditions. Replace the damaged
parts
TROUBL - 41
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
ELECTRICAL SYSTEM DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
Specification
Stop button on rear brake
Light switch
Turn indicator switch
Horn button
Horn
Front turn indicator bulbs
Front left turn indicator
Heater control device
Magneto flywheel
Electronic ignition device
Starter motor
Desc./Quantity
Front turn indicator bulbs 12V-10W x 2
ELE SYS - 43
Electrical system
12
13
14
15
16
Specification
Fuse box
Battery
rear left turn indicator
Rear turn indicator bulbs
Stop and tail light bulb
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Rear light assembly
rear right turn indicator
Voltage regulator
Mixer oil warning light control
Start-up remote control switch
Ground lead (-)
starter motor wire unit
Automatic starter
Carburettor heater
Chassis wire unit
Fuel level transmitter
front right turn indicator
Key switch
Starter button
Front brake stop button
Headlight
Headlight bulb
Front tail light bulb
35
36
37
38
Left turn indicator warning light
Headlight warning light
High-beam warning light
Instrument panel light bulbs
39
40
41
42
Low fuel warning light
Right turn indicator warning light
Low oil warning light
Odometer with warning lights and level indicator
Desc./Quantity
12V - 4Ah
Two, 12V-10W, spherical
Type: Spherical
Power: 12V 21/5W
Quantity: 1
12V-35/35W
Type: All glass
Power: 12V 5W
Quantity: 1
12V - 2W
12V 1.2W
12V - 1.2W
Type: All glass
Power: 12V 1.2W
Quantity: 3
12V - 2W
12V - 1.2W
Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,
Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
Conceptual diagrams
ELE SYS - 44
Electrical system
Ignition
IGNITION
1
2
3
4
5
Specification
Electronic control unit
Magneto flywheel
Pick - up
Key switch
Spark plug
Desc./Quantity
ELE SYS - 45
Electrical system
Headlights and automatic starter section
LIGHTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
ELE SYS - 46
Specification
Voltage regulator
Magneto flywheel
Light switch
Rear light bulb
Headlight bulb
High-beam warning light
N°3 instrument lighting bulbs
Taillight bulb
Headlight warning light
Heater control device
Key switch contacts
Fuse 7,5A
Carburettor heater
Automatic starter
Battery
Desc./Quantity
12V - 5W
12V-35/35W
12V - 1.2W
12V - 1.2W
12V - 5W
12V - 1.2W
12V - 4Ah
Electrical system
Battery recharge and starting
BATTERY RECHARGE AND STARTING
1
2
3
4
5
6
7
8
9
Specification
Magneto flywheel
Voltage regulator
Main fuse
Brake light filament
Front and rear brake light button
Start up button
Starter motor
Remote starter switch
Battery
Desc./Quantity
7,5A
12V - 21W
12V - 4Ah
ELE SYS - 47
Electrical system
Level indicators and enable signals section
START PERMISSIVE BUTTONS AND LEVEL INDICATORS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
ELE SYS - 48
Specification
Magneto flywheel
Voltage regulator
Key switch
Main fuse
Brake light filament
Front and rear brake light button
Start up button
Starter motor
Remote starter switch
Battery
Low oil warning light
Oil level sender
Low fuel warning light
Fuel gauge
Fuel level sender
Desc./Quantity
7,5A
12V - 21W
12V - 4Ah
12V - 1.2W
12V - 1.2W
Electrical system
Turn signal lights
TURN INDICATORS AND HORN
1
2
3
4
5
6
7
8
9
10
Specification
Battery
Main fuse
Key switch
Magneto flywheel
Voltage regulator
Horn button
Horn
Indicators switch
Two (2) turn signal warning light bulbs
4 Turn indicator bulbs
Desc./Quantity
12V - 4Ah
7,5A
12V - 2W
12V-10W
Checks and inspections
1) No-load test: the starter motor, when unloaded,
must absorb no more than 10A with a supply voltage ≥ 12V and must rotate at ≥ 15,000 rpm.
2) Load test: when the starter motor is so braked
that it absorbs 47A with supply voltage ≥ 10V, torque of ≥ 0.2 N•m must be obtained at 10,000 rpm.
3) Static torque test: when the rotor is locked and
the supply voltage is <7V, the absorbed current
must not exceed 130A and the torque must be at
least 0.55 N•m
Specifications
ELE SYS - 49
Electrical system
- Rated voltage 12V.
- Rated power 0.25 kW.
- Left-hand rotation view from pinion side.
- Connected to the engine by pinion and crown wheel on crankshaft, transmission side.
- Push-button control.
- Battery used for the test:12V-3,6Ah.
N.B.
THESE VALUES MUST BE MEASURED WITH A CHARGED BATTERY AND AFTER THE STARTER
HAS BEEN ROTATING FOR 30" UNDER CONDITIONS OF POINT 1
In case the cause of ignition failure or malfunction
cannot be easily identified at sight, first of all replace the control unit by another one in operating
conditions.
Remember that the engine must be off to disconnect and replace the control unit.
If after replacement the vehicle starts properly, the
control unit is failing and must be replaced.
If the failure persists, check the generator and the
stator components as follows:
After visually checking the electrical connections,
use a specific tester to measurement the stator
winding and the pickup (see table).
If any failure is found after checking the loading coil
and the pick-up, replace the stator and the damaged parts.
Disconnect the connector on the flywheel cover
and measure the resistance between either contact and the earthing.
Specific tooling
020331Y Digital multimeter
PICK-UP CHECK
1
Specification
1) Brown cable and earth
Desc./Quantity
~ 170 Ω
STATOR WINDING CHECK
1
ELE SYS - 50
Specification
1) Black cable and earth
Desc./Quantity
~1Ω
Electrical system
Ignition circuit
1) Check the state of the spark plug (clean it with
a metallic brush, remove all incrustations, blow it
with compressed air, and replace it if necessary).
2) Without removing the stator, perform the checks
described below:
After a visual inspection of the electrical connections, carry out the measurements on the charging
coil and pick-up (see table), and check for continuity using the special tester, 020331Y.
If the continuity checks or the inspections on the
coil and pick-up are incorrect, proceed by replacing the stator, otherwise replace the ECU.
Remember to detach the ECU wirings when the
engine is not running.
Specific tooling
020331Y Digital multimeter
PICK - UP CHECK (FIGURE A)
1
Specification
Red cable (1) and White cable (2)
Desc./Quantity
90 ÷ 140 Ohm
RECHARGING COIL CHECK (FIGURE B)
1
Specification
Red cable (3) and Green cable (4)
1
2
Specification
White cable - Engine
White cable - Frame
Desc./Quantity
800 ÷ 1100 Ohm
CONTINUITY CHECK
Desc./Quantity
Continuity
Continuity
ELE SYS - 51
Electrical system
Stator check
- Using a tester, check the resistance between the
stator wiring.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Stator : Grey ÷ Ground
~ 1 ohm
Stator : White ÷ Ground
~ 1 ohm
Stator : Green - Ground
~ 1Kohm
Stator : Blue ÷ Yellow
~ 1 ohm
Pick-Up: Red - ground
~ 170 Ω (Pick-Up)
Voltage regulator check
Voltage regulator
A fault in the voltage regulator can cause the following problems depending on the type of fault:
1) Blow out of the lighting system bulbs.
2) Failure of the lighting system.
3) Excessive battery charging (blowing of main
fuse).
4) Battery recharging failure.
5) Failure of the turn indicators.
6) Failure of the oil and petrol check lamp.
Operations
FAULT 1:
Make sure that at 5000 rpm with the lights on that
the regulation voltage is between 13V and 14.5V.
Make sure that at 5000 rpm with the lights off the
regulation voltage is ï£ 16V.
If the regulation voltage is greater than >16V replace the regulator.
ELE SYS - 52
Electrical system
FAULT 2:
a) Make sure the stator is supplying voltage correctly: disconnect the regulator connector and
place tester 020331 y between the grey-blue wire
(2) and the black wire (6) to measure the alternating voltage and make sure that the voltage supplied at 3000 rpm, is between 25 and 30V (FIG>
A). If there are any anomalies, replace the stator.
b) If the tests do not reveal any anomalies, replace
the regulator.
c) If replacement of the regulator does not restore
correct operation, check the connections of the
electrical system.
FAULT 3
After checking that there are no short circuits in the
system towards earthing with the engine off and
the regulator connector detached, replace the regulator because it is certainly inefficient, and replace the protection fuse.
Following the replacement, measure the current
and the recharging voltage on the battery ends
(FIG. B). The values detected must be 1.5 ÷ 2 A
and 13 V at 3000 rpm.
FAULT 4
a) By positioning tester 020331Y between the yellow wire terminal (8) on the regulator and the black
wire (6) (FIG. D), check the generator output voltage is within 26 and 30 V at 3,000 rpm (this measurement must be carried out with the battery
detached). In the event of anomalies, replace the
stator; otherwise proceed to point b).
b) Yellow wire (1) attached to the regulator. Insert
an ammeter between the stator's blue wire (2) and
the battery, and check, using tester 020331Y, that
the current output, at 3,000 rpm and with the battery kept between 12 and 13V, is approx. 1.5 - 2 A
(FIG. C).
ELE SYS - 53
Electrical system
If the values thus obtained are lower than prescribed, proceed by replacing the regulator. Before
carrying out inspections on the regulator and its
electrical system, it is always advisable to check
for continuity between the black wire and earth.
FAULT 5
(FIG. E) If the turn indicators do not work, proceed
as follows:
- Remove the regulator connector, and insert the
tester probes between the contact 5 (yellow-red)
and the ground lead.
- Turn the key switch to ON and check that the
battery is getting voltage. If no voltage is detected,
check the wiring and the contacts on the key
switch and on the battery.
(FIG. F) Repeat the procedure now placing the
tester probes between contacts 5 (yellow/ red) and
6 (black), and check the presence of the battery
voltage with the key switch set to ON. If there is no
voltage, check the regulator ground wiring.
(FIG. G) If the above tests have positive results,
jump the contacts 5 (yellow/red) and 7 (blue/black)
on the connector, set the key switch to ON and
shift the turn indicator switch to the right and left to
see when the lights are steadily on (as they are
powered directly from the battery). If even after this
operation the turn indicators fail to turn on, check
that the wiring is not damaged and the switch
works properly. If these last two tests have a positive result, replace the regulator because it is certainly not functioning properly.
ELE SYS - 54
Electrical system
FAULT 6
Oil reserve check warning light not working
(FIG H) - Disconnect the voltage regulator connector.
- Supply 12V to the terminal marked with number
5; with a digital tester check that the terminal number 4 has a similar output (12V) for about 5 seconds.
- If no voltage is detected for terminal number 4,
replace the regulator.
- If there is voltage for terminal number 4, check
both the installation and the bulb of the oil warning
light.
Specific tooling
020331Y Digital multimeter
Sealed battery
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 normal 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 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
-Duration of the charge: 5 h
ELE SYS - 55
Electrical system
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.
IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT
TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
1 Hold the vertical tube
2 Look at the level
3 The float must be freed
Dry-charge battery
The battery is an electrical device which requires careful monitoring and diligent maintenance. The
maintenance rules are:
1) Check the level of the electrolyte
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water, to restore this level.
If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works
overcharged and is subject to quick wear.
2)Load status check
After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).
When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific
weight of 1.26 to 1.28 at a temperature of no lower than 15° C.
A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore
be recharged.
After charging the battery, check each element electrolyte level and density. If the scooter is not used
for a given time (1 month or more) it will be necessary to periodically recharge the battery.
The battery runs down completely in the course of three months.
If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering
that the earth wire (black) marked (-) must be connected to the - negative terminal while the other two
red wires marked (+) must be connected to the terminal marked with the + positive sign.
Regular bench charging must be carried out with the specific battery charger, (single) or (multiple),
setting the battery charger selector to the type of battery to be recharged. Connections to the power
supply source must be implemented by connecting the corresponding poles (+ to+ and - to -).
4) Cleaning the battery
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
WARNING
- Before recharging the battery, remove the plugs of each cell. Keep the battery away from naked flames
or sparks when charging.
Remove the battery from the vehicle removing the negative clamp first.
CAUTION
ELE SYS - 56
Electrical system
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.
CAUTION
DRINKING WATER CONTAINS MINERALS THAT CAN BE EXTREMELY HARMFUL TO THE BATTERY: USE DISTILLED WATER ONLY.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT
IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
WARNING
- Battery electrolyte is toxic and it may cause serious burns. It contains sulphuric acid. Avoid contact
with eyes, skin and clothing. In case of contact with eyes or skin, flush abundantly with water for about
15 minutes and seek immediate medical attention.
In the event of accidental ingestion of the fluid, immediately drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg or vegetable oil. Seek immediate medical attention
Batteries produce explosive gases; keep clear of free flames, sparks or cigarettes; ventilate the area
when recharging the battery indoors.
Always protect your eyes when working close to batteries.
Keep out of the reach of children.
1)- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type
specified for batteries, with a specific gravity of 1.26, corresponding to 30° Bé, at a minimum temperature
of 15°C until the upper level is reached.
2) - Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.
3)- Within the following 24 hours, recharge with the specific battery charger (single) or (multiple) at a
density of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corresponding to 31º Bé, and these values are stabilised.
4) - Once the charge is over, level the acid (by adding distilled water). Close and clean carefully.
5)- Once the above operations have been performed, install the battery in the vehicle ensuring the
connections between the wiring and the battery terminals are correct.
WARNING
- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE
THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO
ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
ELE SYS - 57
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
Removal of the engine from the vehicle
Remove the engine from the frame
-Disconnect the battery.
-Remove the muffler assembly.
- Remove the rear wheel.
- Remove the mechanical transmission of the rear brake.
-Disconnect the electric terminals.
- Remove the throttle grip and mixer transmissions.
- Disconnect the hoses (petrol-oil-vacuum-operated cock control).
WARNING
Be very careful when handling fuel.
CAUTION
When installing the battery, first attach the positive cable and then the negative cable.
WARNING
Wear safety goggles when using hitting tools.
ENG VE - 59
INDEX OF TOPICS
ENGINE
ENG
Engine
Automatic transmission
Transmission cover
- Loosen the 15 screws and remove the transmission cover with the aid of a mallet.
N.B.
THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT
FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY
AND THE BEARING HOUSED ON THE CRANKCASE.
Kickstart
- Remove the seeger ring located on the exterior
of the crankshaft.
- Dismantle the dog gear from its seat, slackening
the tension that the toothed sector applies to it by
means of the spring; to do this, it is necessary to
rotate the toothed sector slightly (see the figure).
CAUTION
WHILE REMOVING THE TOOTHED SECTOR, BE VERY
CAREFUL OF THE SPRING TENSION: IT COULD CONSTITUTE A HAZARD FOR THE OPERATOR.
- Upon refitting, apply the recommended grease to
the bushing, to the spring and along the toothed
sector.
- Use the special tool for the charging of the spring,
as shown in the figure.
- Refit the seeger ring after checking that it is in
good condition.
Specific tooling
020261Y Starter spring fitting
Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case
ENG - 61
Engine
Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
- Remove the screws shown in the figure and remove the engine starting lever.
- For the assembly, work in reverse and tighten the
screws to the prescribed torque..
Locking torques (N*m)
Starter lever replacement 12 to 13 Nm
Removing the driven pulley shaft bearing
- Slightly heat the crankshaft from the inside side
to avoid damaging the coated surface and use the
driven pulley shaft or a pin of the same diameter
to remove the bearing.
N.B.
IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DIAMETER EXTRACTOR CAN BE USED.
Refitting the driven pulley shaft bearing
-Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing
after slightly heating the crankcase from the inside.
N.B.
WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.
CAUTION
WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED
SURFACE.
ENG - 62
Engine
Removing the driven pulley
- Lock the clutch bell housing with the specific tool.
- Remove the nut, the clutch bell housing and the
whole of the driven pulley assembly.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Specific tooling
020565Y Flywheel lock calliper spanner
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the inner diameter of the clutch bell.
Characteristic
Clutch bell diameter/standard value
Ø 107+0.2 +0 mm
Clutch bell diameter/max. value allowed after
use
Ø 107.5 mm
Eccentricity measured /max.
0.20 mm
Removing the clutch
- Equip the tool with long pins screwed into position
«A» from the outside, insert the entire driven pulley
in the tool and put the central screw under stress.
CAUTION
THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW
IS TIGHTENED UP TOO FAR.
ENG - 63
Engine
- Using a 34 mm socket wrench remove the clutch
locking nut.
- Loosen the central screw thereby undoing the
driven pulley unit
- Separate the components.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
Inspecting 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 seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT
FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
ENG - 64
Engine
- Remove the three guide pins and the mobile half
pulley.
Removing the driven half-pulley bearing
- Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley.
CAUTION
POSITION THE HOLDING EDGE OF THE EXTRACTION PLIERS BETWEEN THE END OF THE BEARING AND THE
BUILT IN SEALING RING.
Specific tooling
001467Y029 Bell for bearings, O.D. 38 mm
- Remove the ball bearing retention snap ring.
- Expel the ball bearing from the side of the clutch
housing by means of the special tool.
N.B.
PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO
DEFORM THE SLIDING SURFACE OF THE DRIVING BELT
Specific tooling
020376Y Adaptor handle
020363Y 20-mm guide
Inspecting the driven fixed half-pulley
- Check that there are no signs of wear on the work
surface of the belt. If there are, replace the halfpulley..
- Make sure the bearings do not show signs of unusual wear.
- Measure the external diameter of the pulley bushing.
Characteristic
ENG - 65
Engine
Stationary driven half-pulley/Standard diameter
Ø 33.965 to 33.985 mm
Stationary driven half-pulley / Minimum diameter admitted after use
Ø 33.96 mm
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two Orings.
- Measure the inside diameter of the mobile halfpulley bushing.
Characteristic
Mobile driven half-pulley/ Maximum diameter
allowed
Ø 34.08 mm
- Check the belt contact surfaces.
- Insert the new oil seal and O-rings on the mobile
half-pulley.
- Fitting the half-pulley on the bushing.
Recommended products
AGIP GREASE SM 2 Grease for the C-ring of
the tone wheel
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
- Make sure the pins and collar are not worn, reassemble 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 procedure is necessary to prevent the presence of grease beyond the O-ring.
Recommended products
AGIP GREASE SM 2 Grease for the C-ring of the tone wheel
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
ENG - 66
Engine
Refitting the driven half-pulley bearing
- Fit a new ball bearing with the specific tool.
- Fit the ball bearing retention snap ring.
- Fit the new roller bearing with the wording visible
from the outside.
CAUTION
PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT
DAMAGE TO THE THREADED END WHILE THE BEARINGS
ARE BEING FITTED.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020362Y 12 mm guide
020171Y Punch for Ø 17 mm roller case
Inspecting the clutch spring
- Check that the contrast spring of the driven pulley
does not show signs of deformation
- Measure the free length of the spring
Characteristic
Standard length
118 mm
Minimum length allowed after use
XXXX
Refitting the clutch
- Preassemble the driven pulley group with spring,
sheath and clutch.
- Position the spring with the sheath
- Insert the components in the tool and preload the
spring being careful not to damage the plastic
sheath and the end of the threaded bar.
ENG - 67
Engine
- Reassemble the nut securing the clutch and tighten to the prescribed torque.
CAUTION
SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCKET WRENCH WITH SMALL CHAMFER.
CAUTION
POSITION THE NON-CHAMFERED SURFACES OF THE
NUT IN CONTACT WITH THE CLUTCH
Locking torques (N*m)
Nut locking clutch unit on pulley 55 ÷ 60 Nm
Refitting the driven pulley
-Refit the driven pulley assembly, the clutch bell
and the nut, using the specific tool.
Specific tooling
020565Y Flywheel lock calliper spanner
Locking torques (N*m)
Driven pulley shaft nut 40 to 44 Nm
Drive-belt
- Make sure the driving belt is not damaged and
does not have cracks in the toothed grooves.
- Check the width of the belt.
Characteristic
Transmission belt/Minimum width
17.5 mm
ENG - 68
Engine
Removing the driving pulley
- Lock the driving pulley using the appropriate tool.
- Remove the central nut with the related washer,
then remove the drive and the plastic fan.
- Remove the stationary half-pulley.
- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the
rollers and contrast plate fitted loosely on it do not come off.
Specific tooling
020451Y Starting ring gear lock
Mixer gears and belt
- Remove gear and belt.
CAUTION
PAY PARTICULAR ATTENTION TO NOT TOUCHING OR
BENDING THE BELT BECAUSE THIS COULD BREAK SUDDENLY DURING OPERATION.
CAUTION
ON REFITTING, MAKE SURE THAT DIRT DOES NOT GET
INTO THE INNER BUSHING OF THE MIXER CONTROL
GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON
THE CRANKCASE PIN.
N.B.
REPLACE THE BELT EVERY 20000 KM.
Inspecting the rollers case
1) Check that the bushing and the sliding rings of
the mobile pulley do not show signs of scoring or
deformation.
2) Check the roller running tracks on the contact
pulley; there must not be signs of wear and check
the condition of the contact surface of the belt on
the half-pulleys (mobile and stationary).
3) Check that the rollers do not show signs of
marked facetting on the sliding surface and that
the metallic insert does not come out of the plastic
shell borders.
ENG - 69
Engine
4) Check the integrity of the sliding blocks of the
contact plate.
- Check that the internal bushing shown in the figure is not abnormally worn and measure inside
diameter «A».
- Measure outside diameter «B» of the pulley sliding bushing shown in the figure.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHING.
Characteristic
Driving pulley / Maximum diameter:
20.12 mm
Driving pulley/ Standard diameter:
20.021 mm
Driving pulley bushing/ Diameter maximum:
XXX mm
Driving pulley bushing/ Standard diameter:
20 -0.020/-0.041mm
Refitting the driving pulley
- Manually move the movable driven half-pulley
away by pulling it towards the clutch unit and insert
the belt observing the direction of rotation of the
first fitting.
N.B.
IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO
THAT THE WORDS CAN BE READ IN CASE IT DOES NOT
SHOW A FITTING SIDE.
- Refit the components of the assembly (roller container assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive,
washer and nut).
- With the specific tool, tighten the lock nut to 20
Nm and then perform a final 90° locking in order to
prevent the rotation of the driving pulley.
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
CAUTION
UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UTMOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN
ENG - 70
Engine
ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.
Specific tooling
020451Y Starting ring gear lock
Locking torques (N*m)
Crankshaft pulley nut 18 to 20 + 90° Nm
For 25 km/h engine type versions, the limit washer is 5.5 mm thick
End gear
Removing the hub cover
- Drain the rear hub oil
- Remove driven pulley
- Remove the rear brake shoes
- Remove the 5 screws fixing the cover to the
crankcase
- Remove the cover with the wheel axle and pull it
out
- Remove the intermediate gear with the appropriate shim washers
Removing the wheel axle bearings
- Remove the oil seal and the seeger ring.
- Fix the hub cover properly to avoid damaging the
sealing surface with the housing
- Remove the wheel axle bearing using the specific
tool
Specific tooling
020363Y 20-mm guide
020376Y Adaptor handle
ENG - 71
Engine
020477Y 37 mm adaptor
Removing the driven pulley shaft bearing
- Remove the seeger ring
- Heat the engine crankcase but do not direct the
hot air towards the bearing
- Extract the driven pulley shaft together with the
bearing with a few mallet blows
ENG - 72
Engine
- Remove the bearing off the driven pulley shaft
using the specific tool and a press
N.B.
USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALLER INTERNAL DIAMETER
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
Inspecting the hub shaft
- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged components.
- Check capacity ( A ) of the transmission gear
(wear, deformations, etc.)
- Check the pulley shaft seating: Superficial wear
( B ) may indicate irregularities in the crankcase
seatings or in the pulley shaft capacities
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.
- If faults are found, replace the hub cover.
ENG - 73
Engine
Refitting the driven pulley shaft bearing
- Support the inner track of the bearing from the
outside of the hub cover with the specific tool positioned under the press and insert the driven pulley
axle.
- Refit the oil seal flush with the cover.
Specific tooling
020452Y Tube for removing and refitting the
driven pulley shaft
- Slightly heat the hub cover and then fit the bearing with the specific drift.
- Fit the circlip with the concave or radial part facing
the bearing.
N.B.
FIT THE BALL BEARING WITH THE SHIELD FACING THE
OIL SEAL.
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020439Y 17-mm guide
020358Y 37x40-mm Adaptor
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface
- Heat up the hub cover using the thermal gun.
- Preassemble the bearing on the specific punch
using grease and then insert the bearing in its
seating
- Refit the seeger ring and the oil seal using the 42
x 47 mm adaptor
N.B.
POSITION THE OIL SEAL WITH THE SEALING LIP FACING
THE HUB INTERNAL SIDE
Specific tooling
020150Y Air heater mounting
020151Y Air heater
020376Y Adaptor handle
ENG - 74
Engine
020363Y 20-mm guide
020359Y 42x47-mm Adaptor
Refitting the hub bearings
- Remove the wheel axle on the cover and pay attention not to damage the sealing lip of the oil seal
- Apply a thin layer of grease on the two shim
washers of the intermediate gear and fit one on the
cap so that it does not interfere with the wheel axle
gear when placing the transmission shaft
Refitting the ub cover
- Apply product recommended for surfaces on the
hub cap and refit cap on the crankcase
- Fit the 5 screws and tighten them to the specified
torque.
N.B.
CLEAN THE CONTACT SURFACES OF THE HUB COVER
AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BEFORE APPLYING A NEW ONE.
Recommended products
Loctite 510 Liquid sealant
ENG - 75
Engine
Gasket
Locking torques (N*m)
hub cap screws 24 - 26
Flywheel cover
Cooling hood
- Remove the four fixings shown in the figure.
- Remove the fan cover
- Remove the oil piping retention band from the
hood
- Remove the 2 screws shown in the figure
Cooling fan
- Remove the cooling fan by acting on the three
fixings indicated in the figure.
ENG - 76
Engine
Removing the stator
- Remove the three stator fixings shown in the
photo
- Remove the two pick-up fixings shown in the
photo
- Remove the stator with the wiring
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to
the specified torque.
N.B.
THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE
CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEMBLY.
Locking torques (N*m)
Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4
Flywheel and starting
Removing the starter motor
Remove the two clamps shown in the figure
ENG - 77
Engine
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper
spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
- Extract the flywheel with the extractor.
Specific tooling
020565Y Flywheel lock calliper spanner
020162Y Flywheel extractor
Inspecting the flywheel components
- Check the condition of the flywheel and any distortions that might cause rubbing on the stator and
on the Pick-Up.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key
properly.
- Lock the flywheel nut at the prescribed torque
- Check the Pick-Up air gap.
- The air gap may not be modified in the fitting of
the Pick-Up.
- Other values derive from deformations visible on
the Pick-Up support.
ENG - 78
Engine
N.B.
A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO
A VARIATION IN THE IGNITION ADVANCE SUCH AS TO
CAUSE PINGING, KNOCKING ETC.
Locking torques (N*m)
Flywheel nut 40 to 44 N.m
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.
- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.
N.B.
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.
Locking torques (N*m)
Starter screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
Use an anti-tampering TORX spanner to remove
the two clamping screws of the intake manifold
Removing the cylinder head
Remove the 4 screws shown in the figure
ENG - 79
Engine
Removing the cylinder - piston assy.
Remove the cylinder very carefully
Remove the snap rings and remove the pin
CAUTION
AFTER EACH REMOVAL OPERATION REPLACE THE PIN
RETENTION SNAP RINGS
Inspecting the small end
- Measure the internal diameter of the small end
using an internal micrometer.
N.B.
IF THE DIAMETER OF THE ROD SMALL END EXCEEDS
THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF
WEAR OR OVERHEATING REPLACE THE CRANKSHAFT
AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".
Characteristic
Rod small end: standard diameter
17 +0.011-0.001
Rod small end: maximum allowable diameter
17,060 mm
ENG - 80
Engine
Inspecting the wrist pin
- Check the wrist pin external diameter using a micrometer
Characteristic
Wrist pin: standard diameter
12 +0.005 +0.001 mm
Inspecting the piston
- Measure the bearings on the piston using a bore
meter
- Calculate the piston-pin coupling clearance.
Characteristic
Wrist pin housing: standard diameter
12 +0.007 +0.012
Wrist pin housing: standard clearance
0.002 ÷ 0.011 mm
- Measure the outer diameter of the piston, perpendicular to the pin axis.
- Take the measurement in the position shown in
the figure
To classify the cylinder-piston fitting, check the appropriate table
See also
Cylinder - piston assy.
ENG - 81
Engine
Inspecting the cylinder
- Check that the cylinder does not show seizures.
Otherwise, replace it or adjust it respecting the allowable increases
- Measure the internal diameter of the cylinder with
a bore meter, according to the directions given in
the figure
- Check that the fitting surface with the head is not
dented or distorted.
To classify the cylinder-piston fitting, check the appropriate table
See also
Cylinder - piston assy.
Inspecting the piston rings
- Alternatively insert the two sealing rings in the
cylinder
Using the piston, insert the seals perpendicularly
to the cylinder axis.
- Measure the opening of the sealing rings using a
thickness gauge as shown in the photograph
- If the values are higher than the values prescribed in the chart, substitute the rings
Removing the piston
- Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool.
-Push detail 2 into detail 1 until the stop and extract detail 2.
- Insert detail 3 into detail 1, position the assembly in the snap ring assembly area, and push detail 3
all the way in.
N.B.
REFIT THE REMAINING PARTS FOLLOWING THE OPERATIONS IN REVERSE ORDER FROM
THE REMOVAL OPERATIONS
Specific tooling
020166Y Pin lock fitting tool
Locking torques (N*m)
Locking head nuts: 10 to 11 N·m
ENG - 82
Engine
- Use new wrist pin snap rings.
- Use new cylinder base gasket.
- Before refitting carefully clean all the surfaces.
- Use oil to be mixed during the fitting of the piston
and the cylinder.
CAUTION
POSITION THE ARROW PRINTED ON THE PISTON
CROWN TOWARDS THE EXHAUST OPENING.
THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON
THE PISTON WITH THE SPECIFIC TOOL
Recommended products
AGIP CITY TEC 2T Oil
Recommended oil
ENG - 83
Engine
Inspecting the timing system components
CAUTION
CHECK THE CORRECT REED UNIT SEAL; NO LIGHT
MUST PASS BETWEEN THE SUPPORT AND LAMELLA.
Crankcase - crankshaft
Splitting the crankcase halves
Remove the eight crankcase union fasteners.
Install the special strip on the half crankcase on
the flywheel side and separate the half crankcase
on the flywheel side from the transmission side
Specific tooling
020163Y Crankcase splitting plate
ENG - 84
Engine
Removing the crankshaft
- Install the specific tool on the half crankcase on
the transmission side using four M6 screws of an
adequate length.
- Remove the crankshaft from the transmission
side half crankcase
Specific tooling
020163Y Crankcase splitting plate
Removing the crankshaft bearings
The bearings can stay on either the half crankcase
or the crankshaft indifferently
- Using the special tool, remove any bearings that
have been left on the crankshaft
N.B.
The half rings must be inserted on the bearings with a few mallet blows.
Specific tooling
004499Y001 Bearing extractor bell
004499Y006 Bearing extractor ring
004499Y002 Bearing extractor screw
004499Y007 Half rings
- Using the specific tool remove any bearings left
on the half crankcase
Specific tooling
001467Y007 Driver for OD 54 mm bearing
001467Y006 Pliers to extract 20 mm bearings
ENG - 85
Engine
Refitting the crankshaft bearings
Heat the bearings in an oil bath at around 150°C
and fit them on the crankshaft, if necessary using
a section of tube that acts on the bearing's inner
track
Specific tooling
020265Y Bearing fitting base
Inspecting the crankshaft alignment
With the specific tool shown check that the eccentricity of the surfaces of diam. «A»-«B»-« C» are
within 0.03 mm. (reading limit on the dial gauge);
in addition, check the eccentricity of diam. «D», for
which a maximum reading of 0.02 mm is permitted.
In the case where eccentricity is not much above
prescribed levels, straighten the shaft by acting
on the counterweights with a shim or tighten them
in a clamp (with an aluminium bushing) as required..
Specific tooling
020335Y Magnetic mounting for dial gauge
020074Y Mounting base for checking crankshaft alignment
Refitting the crankshaft
- Position the transmission side half crankcase on
two wooden supports
- Using a thermal gun, heat the bearing seat to
about 120°
ENG - 86
Engine
- Firmly insert the crankshaft until the bearing reaches the end-of-stroke stop
- Let the temperature of the half crankcase settle
at the temperature of the crankshaft.
- Again install the special crankcase separation
plate NOT installing the crankshaft protection
- During the assembly phase keep the central
thrust screw loose.
- Take the four clamping screws to the end of the
stroke and loosen them again with the same angle
(e.g. 90°)
- When the temperature has settled, preload the
thrust screw of the tool manually until the ball bearing clearance is cancelled out.
Specific tooling
020163Y Crankcase splitting plate
Refitting the crankcase halves
- Prepare the coupling surface with LOCTITE 510
applying a thin layer of it after degreasing the surface using a suitable solvent (e.g. trichloroethylene)
- Heat the flywheel-side half crankcase with a thermal gun.
Recommended products
Loctite 510 Liquid sealant
Gasket
ENG - 87
Engine
- Keeping the half crankcase on the transmission
side, insert the flywheel side half crankcase with a
clean precise movement
- Insert at least three clamping screws and tighten
up rapidly
- Insert the other 5 screws and tighten them to the
specified torque.
Locking torques (N*m)
crankcase coupling screws 11 - 13
- Move the crankcase separation plate in a position
back from the one indicated in the figure
- Install the special magnetic support with dial
gauge at the end of the crankshaft
- Check the axial clearance of the crankcase
If this is not within the maximum limit allowed, repeat the crankcase coupling procedure
Specific tooling
020335Y Magnetic mounting for dial gauge
Characteristic
Axial clearance with warm crankcase
0.10 ÷ 0.12 mm
Axial clearance with cold crankcase
0.06 to 0.08 mm
Limit value with cold crankcase
0.02 ÷ 0.03 mm
Lubrication
Crankshaft oil seals
ENG - 88
Engine
Refitting
- Install a new flywheel-side oil seal only with the
special tool's punch
The flywheel-side oil seal is recognised by its
smaller diameter
N.B.
THE USE OF THE SPECIFIC TOOL IS NOT COMPATIBLE
WITH THE FITTED WRENCH
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
- Install a new transmission side oil seal using the
special tool with adapter ring.
The transmission-side oil seal is recognised by the
larger diameter
Specific tooling
020340Y Flywheel and transmission oil seals
fitting punch
Oil pump
Removal
- Remove the 2 screws shown in the figure
ENG - 89
Engine
Remove the tube passage seal from the crankcase shown in the figure
Refitting
To refit, perform the steps in the reverse direction
to disassembly
Remember to drain after refitting using the screw
shown in the figure
Fuel supply
- Completely empty the fuel tank.
- Remove the petrol delivery pipe and the lowpressure 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 ORing.
- 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.
ENG - 90
Engine
- 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 suction pipe to the manifold.
- Position the fuel pipe with the outlet at the point
of the tap.
- Turn the engine by using the starter 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 INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION
OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUTLET ON THE MANIFOLD HAS A SECTION INTENTIONALLY
REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Characteristic
Minimum flow rate
20 cc
ENG - 91
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
This section is devoted to operations that can be carried out on the suspensions.
Front
Removing the front wheel
- Remove the wheel axle lock nut.
- Remove the wheel axle and the wheel.
- Upon removal take care not to damage the sensor that detects movement in the odometer.
Front wheel hub overhaul
Ball bearings on wheel hub
- Remove the front wheel
- Keep the wheel level by means of two wooden
wedges
- With the appropriate pliers and tool remove the
wheel bearing on the side the rpm indicator detects
movement, as shown in the photograph
- Remove the internal spacer
- Use appropriate handle, adaptor and guide and
hit with a mallet to extract the bearing and the
spacer bushing on the brake disc side; insert handle on the side the rpm indicator detects movement, as shown in the photo
SUSP - 93
Suspensions
- Check that the bearings do not show flaws or
jamming. Otherwise, replace them.
- Check that the internal spacer does not show abnormal wear. Otherwise, replace it.
- With a hot air gun heat the seat of the bearing on
the brake calliper side
- With an appropriate tool remove the bearing on
the brake disc side
- Insert the spacer bushing on the brake disc side
- With a hot air gun heat the seat of the bearing on
the side the rpm indicator detects movement
- Insert the internal spacer with the centring ring
facing to the brake disc side, as shown in the photo
- Use an appropriate tool to insert the bearing on
the side the rpm indicator detects movement
Specific tooling
001467Y009 Driver for OD 42-mm bearings
001467Y014 Pliers to extract ø 15-mm bearings
020357Y 32x35-mm Adaptor
020376Y Adaptor handle
020412Y 15-mm guide
020456Y Ø 24 mm adaptor
Refitting the front wheel
- Follow the same procedure as per removal but in reverse order, tighten to the specified torque, remember to offset the odometer movement sensor by 90° compared with its own seating on the wheel
so as to avoid damages.
Locking torques (N*m)
Front wheel axle nut 45 - 50
SUSP - 94
Suspensions
Handlebar
Removal
Handlebars removal
Remove the handlebar cover before carrying out
this operation,.
- After removing the transmissions and disconnecting the electrical terminals, remove the terminal fixing the handlebar to the steering.
- Check all components and replace faulty parts.
N.B.
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE
THE STEERING, TILT THE HANDLEBAR FORWARD TO
AVOIDING DAMAGING THE TRANSMISSIONS.
Refitting
Carry out the removal operations but in the reverse
order, observing the prescribed tightening torque.
Locking torques (N*m)
Handlebar fixing screw 50 ÷ 55
Front fork
Overhaul
Seal replacement and stanchion removal
- Remove the wheel axle.
- Remove the lower screw (1).
- Discharge the oil in the suspension.
- Remove the stem.
- Replace the sealing rings (3-4) with new ones.
- Insert the new sealing rings only after lubricating
their seatings.
- Refit the stem and the lower screw (1).
SUSP - 95
Suspensions
- Remove the upper screw (2).
- Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for
forks).
- Refit all components.
Locking torques (N*m)
Upper screw tightening torque 20 to 25 Nm Lower
screw tightening torque: 20 to 25 Nm
Steering column
Refitting
Lower and upper bearing races to frame
Lower and upper seating on the chassis
LOWER AND UPPER SEATING ON THE CHASSIS
Titolo
Durata/
Valore
Testo Breve
(< 4000 car.)
Indirizzo
Immagine
Lower and
upper seating
on the chassis
Steering bearing
Steering locking ring nut
Steering lock ring nut
Top washer and upper bearing housing
- Lubricate race and balls with Z2 grease.
- Tighten to the specified torque and then rotate
the tool through 80° - 90° in an anticlockwise direction.
Removal
Lower and upper races from frame
SUSP - 96
Suspensions
To remove the bearing seats from the chassis, use
the appropriate tool as shown in the figure.
N.B.
To remove the lower seating of the lower bearing just use a
screwdriver as a lever between the seating and the shell.
LOWER AND UPPER SEATING FROM THE CHASSIS
Titolo
Lower and upper seating from
the chassis
Durata/Valore
Testo Breve (< 4000 car.)
Indirizzo Immagine
Top washer and upper bearing housing
After removing the upper seating, tilt the vehicle to
a side and take out the steering tube making sure
mudflaps have been removed and the calliper disconnected.
Rear
Removing the rear wheel
- Use a screwdriver as a lever between the drum
and the cover.
-Straighten the split pin and remove the cap.
-Remove the wheel acting on the central fixing
point.
WARNING
-ALWAYS USE NEW SPLIT PINS FOR REFITTING.
SUSP - 97
Suspensions
Refitting the rear wheel
-Refit the parts in the reverse order as for removal,
lock the wheel nut to the specified torque.
WARNING
- FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN ORDER TO AVOID BACKSLASH BETWEEN THE CAP AND
THE WHEEL AXLE.
Locking torques (N*m)
Rear wheel axle 104 ÷ 126
Shock absorbers
Removal
- To replace the shock absorber remove the rear
cover and battery access flap to get and remove
the shock absorber/ chassis anchoring nut. Then
remove the shock absorber/engine anchorage
nut.
- When refitting, tighten the shock absorber/chassis anchoring nut and the shock absorber/engine
pin to the prescribed torque.
Locking torques (N*m)
Shock absorber/engine pin torque 33 to 41 N·m
Shock absorber/frame nut torque 20 to 25 Nm
Centre-stand
Centre-stand bolt refitting and caulking to mounting bracket
- Caulk the end of the pin «P» between the two
punches shown in the figure.
- After caulking it must be possible for the stand to
turn freely.
N.B.
UPON REFITTING USE NEW O-RING AND PIN, GREASE
THE SPRING ATTACHMENTS AND THE PIN.
Centre-stand assy. removal
SUSP - 98
Suspensions
- Work on the screws shown in the figure.
- When refitting, secure to the prescribed torque.
Locking torques (N*m)
Stand screw torque 18.5 to 19 Nm
Centre-stand bolt removal from mounting bracket
- Remove the stand support bracket from the engine.
- Drill a 5 mm hole in the bracket so that the pin
«P» can come out.
SUSP - 99
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
Once the muffler and the wheel have been removed, follow these steps:
1.Remove the shoe spring using the specific spanner.
2. Remove the shoe with the aid of a lever.
3. Refit the new shoes giving a few taps with the
mallet.
4. Attach the spring using the specific pliers.
Specific tooling
020325Y Pliers for brake-shoe springs
Front brake calliper
Overhaul
- Remove the calliper assembling bolts and take out the internal bodies and components. If necessary,
in order to make it easier to take out the plungers, inject (shorts blasts of) compressed air through the
brake fluid pipe.
- Check that the cylinders of the internal and external body of the calliper do not show scratches or signs
of erosion; otherwise, replace the entire calliper.
CAUTION
ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS
SERVICED.
Front brake disc
Disc Inspection
- Remove the wheel and check for unevenness of
the disc.
Maximum permissible out of true is 0.1 mm. If the
value measured is greater, fit a new disc and repeat the check.
- If the problem persists, check and replace the
wheel rim if necessary.
Specific tooling
020335Y Magnetic mounting for dial gauge
BRAK SYS - 101
Braking system
Front brake pads
Removal
- To facilitate this operation remove the two calliper
fixings. With the calliper detached from its support
but still connected to the brake fluid line, remove
the plastic cover by prising it with a screwdriver.
- Remove the outside circlip from the brake pad
pin, the leaf spring and the pads.
- Renew the pads when friction facing thickness is
less than 1.5 mm.
Fill
Front
-Once the bleed valve is closed, fill the system with
brake liquid 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.
IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS:
IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, 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.
BRAK SYS - 102
Braking system
DURING PURGING FREQUENTLY CHECK THE LEVEL TO
PREVENT AIR GETTING INTO THE SYSTEM THROUGH
THE PUMP.
WARNING
- BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR.
IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE
REDUCED.
THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS.
UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS
YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS.
IF THE BRAKES ARE USED INTENSELY AND/OR IN
HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID
MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS
SEAT ON THE CALLIPER.
CAREFULLY DRY THE CALLIPER AND DEGREASE THE
DISC SHOULD THERE BE OIL ON IT.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Recommended products
AGIP BRAKE 4 Brake fluid
FMVSS DOT 4 Synthetic fluid
Locking torques (N*m)
Oil bleed screw 8 ÷ 12
Front brake pump
-After removing the front and rear handlebar covers, act on the two stand fixing points (see the figure).
- Disconnect the tube, collecting the brake oil in a container.
- On refitting, perform the operation in reverse.
- Tighten the hydraulic line to the prescribed torque
and bleed the system.
Locking torques (N*m)
Brake fluid pump - hose fitting 20 ÷ 25 Nm
BRAK SYS - 103
Braking system
Removal
- Bleed the circuit and drain the brake fluid through
the bleeding screw located on the calliper and actuate the brake lever until no more fluid flows out.
-Remove the oil pump from the handlebar; remove
the brake lever and then remove the wheel cylinder.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
5. Sealing ring.
6. Piston.
7. Gasket.
8 - Spring
CAUTION
- THE PRESENCE OF BRAKE FLUID ON THE DISC OR
BRAKE PADS REDUCES THE BRAKING EFFICIENCY.
IN THIS CASE, REPLACE THE PADS AND CLEAN THE
DISC WITH A HIGH-QUALITY SOLVENT.
CONTACT WITH BRAKE FLUID WILL DAMAGE PAINTED
SURFACES.
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL
FOR LONGER THAN 20 SECONDS.
AFTER WASHING, THE PIECES MUST BE DRIED WITH A
BLAST OF COMPRESSED AIR AND A CLEAN CLOTH.
THE SEALING RINGS MUST BE IMMERSED IN THE OPERATING LIQUID.
Refitting
Before fitting, the parts must be perfectly clean and
free of traces of oil, diesel fuel, grease, etc.. They
should be washed thoroughly in denatured alcohol
before proceeding.
- Reinstall the individual parts in the reverse order
to the removal, paying attention to the correct positioning of the rubber parts in order to ensure leak
tightness.
1 - Tank cap screw.
2. Tank cover.
3. Diaphragm.
4. Bellows.
BRAK SYS - 104
Braking system
5. Sealing ring.
6. Piston.
7. Gasket.
8. Spring.
BRAK SYS - 105
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Carrozzeria
Removing the ignition key-switch when on *off*
• Remove the shield back plate
• Push the lock body until the stop spring does not
show grooves.
• Keep the lock body blocked with a screwdriver
and remove the spring with a pair of pliers.
• Take out the lock block.
Removing the ignition key-switch when on *lock*
Remove the shield.
- Remove the switch of the key switch.
- Make a hole on the block using a drill as shown
in the figure.
- Insert the wheel cylinder with the key and with the
anchoring tab facing down halfway on the lock
body taking care that the insertion phase of the key
is oriented matching "ON" (the only position that
enables the cylinder to get into the lock body); now
turn the key leftwards to "OFF" and at the same
time press until the cylinder is completely in.
Footrest
- Remove the side fairings
- Remove the shield back plate
- Remove the 6 screws shown in the photograph
CHAS - 107
Chassis
Rear mudguard
- Remove the side fairings
- Remove the 4 screws shown in the photograph
Helmet bay
- Remove the side fairings
- Remove the helmet compartment by undoing the
4 screws indicated in the figure
CHAS - 108
Chassis
Fuel tank
- Remove the side fairings
- Remove the rear mudguard
- Remove the crews shown in the photograph
- Remove the shock absorber upper clamping in
order to create the necessary space to take out the
tank.
CHAS - 109
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
Lock check
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high-beam lights, low-beam lights, tail and parking lights and their warning lights
- Adjusting the headlights according to the regulations currently 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 - 111
Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN 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 coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
Static test
Static control after the test ride:
PRE DE - 112
Pre-delivery
- Starting when warm
- Starter operation
- Minimum hold (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 OR TYRES MAY BURST.
Functional inspection
Functional check up:
Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 113
INDEX OF TOPICS
TIME
TIME
Time
This section is devoted to the time necessary to
carry out repairs.
The description and code for each operation is indicated.
Engine
ENGINE
1
Code
001001
Action
engine from frame - removal and refitting
Duration
TIME - 115
Time
Crankcase
CRANKCASE
1
TIME - 116
Code
001133
Action
Engine crankcase - Replacement
Duration
Time
Crankshaft
CRANKSHAFT
1
2
3
4
Code
001118
001100
001099
001117
Action
Main bearings - Replacement
Clutch-side oil seal - Replacement
Oil seal, flywheel side - Replacement
Crankshaft - Replacement
Duration
TIME - 117
Time
Cylinder assy.
CYLINDER- PISTON
1
2
TIME - 118
Code
001002
001107
Action
Cylinder-Piston - Replacement
Cylinder / piston - Inspection / cleaning
Duration
Time
Cylinder head assy.
HEAD
1
2
3
4
5
Code
001097
001093
001126
001013
001178
Action
Cooling hood - Replacement
Spark plug - Replacement
Head - Replacement
Intake manifold - Replacement
Disc pack - Replacement
Duration
TIME - 119
Time
Driven pulley
DRIVEN PULLEY - CLUTCH
1
2
3
4
TIME - 120
Code
001012
001110
001022
001155
Action
Driven pulley - overhaul
Driven pulley- Replacement
Clutch - Replacement
Clutch bell housing - Replacement
Duration
Time
Oil pump
OIL PUMP
1
Code
001028
2
3
001019
001018
Action
Mix movement gear socket - Replacement
Mixer belt - replacement
Mixer - Replacement
Duration
TIME - 121
Time
Driving pulley
DRIVING PULLEY
1
2
3
4
TIME - 122
Code
001066
001086
001011
001177
Action
Driving pulley - Removal and refitting
Driving half-pulley - replace
Driving belt - Replacement
Variator rollers / shoes - Replacement
Duration
Time
Transmission cover
TRANSMISSION COVER
1
2
Code
001087
001135
3
001096
Action
Flywheel cover - Replacement
Transmission cover bearing - Replacement
Transmission crankcase cover - Replacement
Duration
TIME - 123
Time
Flywheel magneto
FLYWHEEL - FAN
1
2
3
4
TIME - 124
Code
001109
001173
001067
001058
Action
Cooling fan - Replacement
Rotor - Replacement
Stator - Fitting and Refitting
Flywheel - Replacement
Duration
Time
Carburettor
CARBURATOR
1
2
3
Code
001008
001063
007020
4
001081
Action
Carburettor - Inspection
Carburettor - Replacement
Carburettor heating tubing - replacement
Automatic choke - Replacement
Duration
TIME - 125
Time
Exhaust pipe
MUFFLER
1
2
3
TIME - 126
Code
001009
001095
001136
Action
Muffler - Replacement
Muffler guard - Replacement
Exhaust emissions - Adjustment
Duration
Time
Air cleaner
AIR CLEANER
1
Code
004122
2
3
001014
001015
Action
Air cleaner carburettor fitting - Replacement
Air filter - Replacement / cleaning
Air filter box - Replacement
Duration
TIME - 127
Time
Frame
STAND
1
2
3
TIME - 128
Code
004001
004004
001053
Action
Frame - replace
Stand - Replacement
Stand bolt - Replacement
Duration
Time
Legshield spoiler
FRONT SHIELD SPOILER
1
2
3
Code
004159
004149
004064
4
5
004015
004053
Action
Plates / Stickers - Replacement
Shield central cover - Replacement
Front shield, front part - Removal and
refitting
Footrest - Removal and Refitting
Spoiler - Replacement
Duration
TIME - 129
Time
Rear cover
REAR SHIELD
1
2
Code
004174
004065
3
004081
TIME - 130
Action
Trunk levers - Replacement
Legshield, rear part - Removal and
refitting
Top box lid - Replacement
Duration
Time
Central cover
CENTRAL COVER
1
Code
004059
2
3
4
5
004106
004085
004105
004131
Action
Spark plug inspection flap - Replacement
Under-saddle band - Replacement
Fairing (1) - Replacement
Right side clamp - Replacement
Luggage rack support - Replacement
Duration
TIME - 131
Time
Mudguard
MUDGUARDS
1
2
TIME - 132
Code
004002
004009
Action
Front mudguard - Replacement
Rear mudguard - Replacement
Duration
Time
Fuel tank
FUEL TANK
1
2
3
Code
004168
005010
004112
4
5
6
004005
004007
004109
Action
Fuel tank cap - Replacement
Tank float - Replacement
Cock-carburettor hose - Replacement
Fuel tank - Replacement
Fuel valve - Replacement
Fuel tank breather - change
Duration
TIME - 133
Time
Tank oil
OIL RESERVOIR
1
2
3
4
Code
005018
004017
004095
004091
Rear shock-absorber
TIME - 134
Action
Oil reservoir float - Replacement
Oil reservoir - Replacement
Oil reservoir cock - Replacement
Oil reservoir hose - Replacement
Duration
Time
REAR SHOCK ABSORBER
1
Code
003007
Action
Rear shock absorber - Removal and
Refitting
Duration
Steering column bearings
STEERING FIFTH WHEELS
1
2
3
Code
003051
003002
003073
Action
Complete fork - Replacement
Steering fifth wheels - Replacement
Steering clearance - Adjustment
Duration
TIME - 135
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004019
2
004018
3
4
5
6
005078
005076
005014
005038
TIME - 136
Action
Handlebar rear section - Replacement
Handlebar front section - Replacement
Odometer glass - Replacement
Clock / Cell - Replacement
Odometer - Replacement
Instrument panel warning light bulbs
- Replacement
Duration
Time
Handlebar components
HANDLEBAR COMPONENTS
1
2
3
4
5
6
Code
004066
002037
002071
003001
005017
002024
7
002054
8
002060
9
004162
10
002059
Action
Driving mirror - Replacement
Brake or clutch lever - Replacement
Left hand grip - Replacement
Handlebar - Replacement
Stop switch - Replacement
Front brake pump - Removal and Refitting
Throttle or splitter transmission complete - Replacement
Complete throttle control - Replacement
Mirror support and/or brake pump fitting U-bolt - Replacement
Right hand grip - Replacement
Duration
TIME - 137
Time
Swing-arm
SWINGING ARM
1
TIME - 138
Code
001072
Action
Engine-frame connection swinging
arm - Replacement
Duration
Time
Seat
SADDLE
1
2
Code
004003
004068
Action
Saddle - Replacement
Passenger handgrip - Replacement
Duration
TIME - 139
Time
Turn signal lights
TURN INDICATOR LIGHTS
1
2
3
Code
005002
005012
005067
4
5
6
7
005008
005005
005066
005022
8
005068
TIME - 140
Action
Front headlamp - Replacement
Front turn indicator - Replacement
Front turn indicator bulb - Replacement
Headlight bulbs - Replacement
Taillight - change
Rear light bulbs - Replacement
Rear turning indicators - Replacement
Rear turning indicator bulb - Replacement
Duration
Time
Front wheel
FRONT WHEEL
1
2
Code
003038
002011
3
4
5
003040
003047
003037
6
7
004123
002041
Action
Front wheel axle - Remov. and refitt.
Odometer movement sensor - Replacement
Front wheel bearings - Replacement
Front tyre - Replacement
Front wheel rim - Removal and Refitting
Front wheel - Replacement
Front brake disc - Replacement
Duration
Grease tone wheel or drive
Please take note that the code has been introduced:
900001 - Tone wheel / drive greasing - 15'.
Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated
components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide).
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 141
Time
Rear wheel
REAR WHEEL
1
2
Code
004126
001071
3
4
001016
002002
TIME - 142
Action
Rear wheel tyre - Replacement
Rear wheel rim - Removal and Refitting
Rear wheel - Replacement
Rear brake pads/shoes - Repl.
Duration
Time
Electric start
ELECTRICAL START-UP
1
2
Code
001020
005045
3
001017
4
5
6
001021
008008
001084
Action
Starter motor - Replacement
Starter motor cable harness - Replacement
Starter sprocket wheel - Replacement
Kick starter - Inspection
Starter spring pack - Replacement
Starter lever - Replacement
Duration
TIME - 143
Time
Electric devices
ELECTRICAL DEVICES
1
2
3
4
TIME - 144
Code
005007
005011
005052
005054
Action
Battery - change
Start-up contactor - Replacement
Fuse (1) - Replacement
Fuse block (1) - Replacement
Duration
Time
ELECTRICAL DEVICES
1
2
3
4
5
Code
005001
005009
001094
001023
005114
Action
Electrical system - Replacement
Voltage regulator - Replacement
Spark plug cap - Replacement
Control unit - Replacement
Electrical system - Service
Duration
TIME - 145
Time
Electronic controls
ELECTRIC CONTROLS
1
2
Code
005039
005006
3
4
5
6
7
005040
005003
005041
005016
004096
TIME - 146
Action
Lights switch - Replacement
Light or turning indicator switch - Replacement
Horn button - Replacement
Horn - Replacement
Starter button - Replacement
Key switch - Replacement
Lock series - Replacement
Duration
Time
Transmissions
TRANSMISSION
1
Code
002051
2
3
002012
002057
4
002058
5
002053
6
7
002049
003061
Action
Odometer transmission assembly Replacement
Splitter - Replacement
Carburettor / splitter transmission
complete - Replacement
Mix / splitter transmission complete Replacement
Rear brake transmission complete Replacement
Odometer cable - Replacement
Accelerator transmission - adjust
Duration
TIME - 147
Time
Brake callipers
CALLIPER
1
Code
002021
2
002007
3
002039
4
002047
TIME - 148
Action
Front brake hose - Remov. and Refitt.
Front brake shoes/pads - Remov.
and Refitt
Front brake calliper - Removal and
Refitting
Front brake fluid and air bleed system - Replacement
Duration
Time
Steering column
STEERING
1
2
3
4
Code
003048
003076
003079
003010
Action
Fork oil seal - Replacement
Fork sheath - Replacement
Fork stem - Replacement
Front suspension - Service
Duration
TIME - 149
Time
Helmet bay
HELMET COMPARTMENT
1
Code
004016
2
005046
TIME - 150
Action
Helmet compartment - Removal and
Refitting
Battery cover - change
Duration
Time
Rear wheel axle
REAR WHEEL AXLE
1
Code
001156
2
3
4
004125
001010
003065
Action
Gear reduction unit cover - Replacement
Rear wheel axle - Replacement
Geared reduction unit - Service
Gear box oil - Replacement
Duration
TIME - 151
Time
Secondary air box
SECONDARY AIR HOUSING
1
Code
001164
2
001161
3
001162
4
001163
5
001165
TIME - 152
Action
Crankcase secondary air connection
- Replacement
Secondary air filter - Replacement /
Cleaning
Secondary air housing - Replacement
Muffler secondary air connection Replacement
Secondary air reed - Replacement
Duration
A
Air filter: 30
B
Battery: 40, 47, 55, 56
Brake: 101–103, 148
C
Carburettor: 11, 27, 125
E
Engine stop:
F
Fuel: 39, 90, 109, 133
H
Headlight: 33
Horn:
Hub oil: 29
I
Identification: 8
M
Maintenance: 7, 25
S
Saddle:
Shock absorbers: 98
Spark plug: 28
Stand:
Start-up:
T
Tank: 109, 133, 134
Transmission: 10, 39, 61, 123
Turn indicators:
Tyres: 10
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