WORKSHOP MANUAL Liberty 125

WORKSHOP MANUAL Liberty 125
WORKSHOP MANUAL
633120
Liberty 125 - 200 4tempi
WORKSHOP
MANUAL
Liberty 125 - 200 4tempi
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all countries. The availability of single models
should be checked at the official Piaggio sales network.
"© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
WORKSHOP MANUAL
Liberty 125 - 200 4tempi
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
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
Liberty 125 - 200 4tempi
Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid open flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point 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 made properly, particularly the ground and battery connections.
CHAR - 7
Liberty 125 - 200 4tempi
Characteristics
Vehicle identification
VEHICLE IDENTIFICATION (125)
Specification
Chassis prefix (125)
Engine prefix (125)
Desc./Quantity
ZAPM38100 ÷ 1001
M381M ÷ 1001
VEHICLE IDENTIFICATION (200)
Specification
Chassis prefix (200)
Engine prefix(200)
Desc./Quantity
ZAPM38400 ÷ 1001
M384M ÷ 1001
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Dry weight
Width
Length
Wheelbase
Saddle height
CHAR - 8
Desc./Quantity
99 kg
735 mm
1935 mm
1335 mm
775 mm
Liberty 125 - 200 4tempi
Characteristics
Engine
ENGINE
Specification
Engine
Timing system
Valve clearance
Bore x stroke (125)
Bore x stroke (200)
Cubic capacity (125)
Cubic capacity (200)
Compression ratio (125)
Compression ratio (200)
Carburettor
Engine idle speed
Start-up
Maximum power to crankshaft (125)
Maximum power to crankshaft (200)
Cooling
Desc./Quantity
Single-cylinder, 4-stroke Piaggio LEADER
Single overhead camshaft (SOHC) with 2 valves
intake 0.10
outlet 0.15
57 x 48.6 mm
72 x 48.6 mm
124 cm³
197 cm³
10.6 : 1
9,5:1
KEIHIN CVEK26
approx. 1.600 ÷ 1.800 rpm
Electric
10.5 CV at 8000 rpm
12.5 CV at 6500 rpm
Forced air circulation.
CHAR - 9
Liberty 125 - 200 4tempi
Characteristics
Transmission
TRANSMISSION
Specification
Transmission
Desc./Quantity
With automatic expandable pulley variator with torque server,
V belt, automatic clutch, gear reduction unit and transmission
housing with forced air circulation cooling.
Capacities
CAPACITIES
Specification
Engine oil
Rear hub oil
Fuel tank capacity (125)
Fuel tank (200 cc.)
Desc./Quantity
61 in³ (1,000 cm³)
~ 200 cm³
~ 6 litres (of which 1.5 litres is reserve)
~ 9 litres (including 1,5 litre reserve)
Electrical system
ELECTRICAL COMPONENTS
Specification
Start-up
Spark plug (125)
Spark plug
Desc./Quantity
Electric
Champion RG6YC- NGK CR7EB
Champion RG6YC
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Chassis
Front suspension
Rear suspension
Desc./Quantity
Steel tube chassis
Ø 32 Hydraulic telescopic fork - travel: 76 mm
Hydraulic single shock absorber and spring adjustable to 4 positions at preloading; travel: 85.5 mm.
Brakes
BRAKES
Specification
Front brake
Rear brake
Desc./Quantity
Ø 220 mm disc with calliper with counteracting pistons.
Drum brake, Ø 140 mm
Wheels and tyres
WHEELS AND TYRES
Specification
Front wheel rim
Rear wheel rim
Front tyre (125)
Rear tyre (125)
Front tyre (200)
Rear tyre (200)
CHAR - 10
Desc./Quantity
Die-cast aluminium alloy, 2.15 x16"
Die-cast aluminium alloy, 2.75 x14"
Tubeless 90/80 - 16
Tubeless 110/80-14"
Tubeless 100/80-16"
Tubeless 120/70 - 14"
Liberty 125 - 200 4tempi
Specification
Front tyre pressure
Rear tyre pressure
Rear tyre pressure (rider and luggage)
Characteristics
Desc./Quantity
2 bar
2.2 bar
2.5 bar
Secondary air
In order to reduce polluting emissions, the vehicle
is furnished with a catalytic converter in the muffler.
To favour the catalytic process, an extra amount
of oxygen is added via a secondary air system
(SAS).
This system allows more oxygen to be added to
the unburned gases before they reach the converter, thus improving the action of the catalytic
converter.
The air enters the exhaust duct from the head, and
is purified by a black filter.
The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise.
To ensure the best functioning of the SAS system,
every 12,000 km the scooter should be taken to an
Authorised Piaggio Service Centre to have the
filter cleaned (Scheduled maintenance operations
section).
The filter sponge should be cleaned with water and
mild soap, then it should be dried with a cloth and
slight blows of compressed air.
CAUTION
CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE
TO CARRY OUT THESE OPERATIONS.
Carburettor
125cc Version
CHAR - 11
Liberty 125 - 200 4tempi
Characteristics
Kehin
CARBURETTOR SETTING
Specification
Type
Throttle valve diameter
Diffuser diameter
Setting stamping
Maximum jet
Maximum air jet (on the body)
Tapered pin stamping
Throttle valve spring
Minimum jet
Idle air jet (on the body)
Idle mixture adjustment screw initial opening
Starter jet
Starter air jet (on the body)
Starter pin travel
Starter resistance
Desc./Quantity
CVEK26
Ø 26.5
Ø 26.4
262A
82
85
NELA
130 ÷ 180 gr.
35
150
1¾
42
Ø 1.5
10 mm (at 24°)
20 Ohm (at 24°)
200cc Version
Kehin
CARBURETTOR SETTING
Specification
Type
Throttle valve diameter
Diffuser diameter
Setting stamping
Maximum jet
Maximum air jet (on the body)
Tapered pin stamping
Throttle valve spring
Minimum jet
Idle air jet (on the body)
Idle mixture adjustment screw initial opening
Starter jet
Starter air jet (on the body)
Starter pin travel
Starter resistance
Desc./Quantity
CVEK26
Ø 26.5
Ø 26.4
265A
82
85
NELA
130 ÷ 180 gr.
35
150
1¾
42
Ø 1.5
10 mm (at 24°)
20 Ohm (at 24°)
Tightening Torques
MOTORE
Name
Ignition spark plug
Head cover screws
Head-cylinder stud bolt nuts
Screws fixing head and cylinder to crankcase
Chain tensioner pad screw
Timing chain tensioner screws
Timing chain tensioner central screw
Camshaft pulley screw
Rocking lever axle and camshaft bearing screw
Valve clearance adjustment lock nuts
Engine oil pre-filter cover:
Engine oil drainage cap
CHAR - 12
Torque in Nm
10 ÷ 15 Nm
8 ÷ 10
6 ÷ 7 + 90° + 90° *
8 ÷ 10
5 ÷ 7 Nm
8 ÷ 10 Nm
5-6
12 ÷ 14
3 ÷ 4 Nm
7 ÷ 9 Nm
25 ÷ 28 Nm
25 ÷ 28
Liberty 125 - 200 4tempi
Characteristics
Name
Alternator flywheel nut
Stator screws
Pick-up screws
Oil pump bulkhead screw
Timing chain/oil pump compartment cover screws
Oil decantation labyrinth sheet screws
Oil pump crown screw
Screws fixing oil pump to crankcase
Oil pump coupling screws
Oil sump screws
Inlet manifold screw
Carburettor/manifold clamp screw
Screws fixing cables to starter motor
Starter motor screws
Transmission cover screws
Crankcase cooling cover screw
Nut locking clutch unit on pulley
Crankshaft pulley nut
Driven pulley shaft nut
Hub oil drainage screw
Rear hub cap screws
Wheel axle nut
Crankcase half union screw
Torque in Nm
40 ÷ 44 Nm
3÷4
3÷4
4÷5
4 ÷ 5 Nm
7÷8
8 ÷ 10
5÷6
7 ÷ 9 Nm
8 ÷ 10 Nm
7÷9
1.2 ÷ 1.5 Nm
1.5 ÷ 2.5
11 ÷ 13
11 ÷ 13 Nm
2 ÷ 2.5
55 ÷ 60 Nm
18 to 20 + 90° Nm
40 ÷ 44 Nm
3 ÷ 5 Nm
24 ÷ 26 Nm
115 ÷ 125
8 ÷ 10
Per assicurare una corretta coppia di bloccaggio lubrificare i dadi prima del montaggio.
* Montando dei nuovi prigionieri, l'operazione di serraggio dei dadi comprende l'effettuazione di 3 rotazioni di 90° dopo il primo
bloccaggio a 6÷7 Nm, pertanto: 6÷7 Nm + 90° + 90° + 90° a passaggi incrociati.
STEERING ASSEMBLY
Name
Upper steering ring nut
Steering lower ring nut
handlebar fixing screw
Torque in Nm
35 ÷ 40
12 ÷ 14
45 ÷ 55
FRAME ASSEMBLY
Name
Engine-swinging arm bolt
Frame-swinging arm bolt
Shock absorber - chassis nut
Shock absorber/engine pin
Rear wheel axle
Stand bolt
Front mudguard fixing screw
Torque in Nm
33 ÷ 41
64 - 72
20 ÷ 25
33 - 41 N.m
104 ÷ 126
20 ÷ 25
4÷6
FRONT SUSPENSION
Name
Fork bottom screw
Front wheel axle
Odometer drive screw
Torque in Nm
20 ÷ 25
45 ÷ 50
6÷7
FRONT BRAKE
Name
Brake fluid pump-hose fitting
Brake fluid pipe-calliper fitting
Calliper tightening screw
Disc tightening screw (Apply LOCTITE 243 medium-strength
threadlocker)
Oil bleeding valve
Torque in Nm
20 ÷ 25
20 ÷ 22
20 ÷ 25
8 ÷ 12 Nm
8 ÷ 12
Overhaul data
CHAR - 13
Liberty 125 - 200 4tempi
Characteristics
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND ALUMINIUM CYLINDER WITH CAST IRON LINER
(125)
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st increase
Coupling 1st increase
Coupling 1st increase
Coupling 1st increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 2nd increase
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
A
B
C
D
A1
B1
C1
D1
A2
B2
C2
D2
A3
B3
C3
D3
Cylinder
56.980 ÷ 56.987
56.987 ÷ 56.994
56.994 ÷ 57.001
57.001 ÷ 57.008
57.180 ÷ 57.187
57.187 ÷ 57.194
57.194 ÷ 57.201
57.201 ÷ 57.208
57.380 ÷ 57.387
57.387 ÷ 57.394
57.394 ÷ 57.401
57.401 ÷ 57.408
57.580 ÷ 57.587
57.587 ÷ 57.594
57.594 ÷ 57.601
57.601 ÷ 57.608
Piston
56.933 ÷ 56.940
56.940 ÷ 56.947
56.947 ÷ 56.954
56.954 ÷ 56.961
57.133 ÷ 57.140
57.140 ÷ 57.147
57.147 ÷ 57.154
57.154 ÷ 57.161
57.333 ÷ 57.340
57.340 ÷ 57.347
57.347 ÷ 57.354
57.354 ÷ 57.361
57.533 ÷ 57.540
57.540 ÷ 57.547
57.547 ÷ 57.554
57.554 ÷ 57.561
Play on fitting
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
0.040 - 0.054
PISTON TO CAST IRON CYLINDER COUPLING (125)
Name
Coupling
Coupling
Coupling
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
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
M
N
O
P
M1
N1
O1
P1
M2
N2
O2
P2
M3
N3
O3
P3
Cylinder
56.997 ÷ 57.004
57.004 ÷ 57.011
57.011 ÷ 57.018
57.018 ÷ 57.025
57.197 ÷ 57.204
57.204 ÷ 57.211
57.211 ÷ 57.218
57.218 ÷ 57.225
57.397 ÷ 57.404
57.404 ÷ 57.411
57.411 ÷ 57.418
57.418 ÷ 57.425
57.597 ÷ 57.604
57.604 ÷ 57.611
57.611 ÷ 57.618
57.618 ÷ 57.625
Piston
56.944 ÷ 56.951
56.951 ÷ 56.958
56.958 ÷ 56.965
56.965 ÷ 56.972
57.144 ÷ 57.151
57.151 ÷ 57.158
57.158 ÷ 57.165
57.165 ÷ 57.172
57.344 ÷ 57.351
57.351 ÷ 57.358
57.358 ÷ 57.365
57.365 ÷ 57.372
57.544 ÷ 57.551
57.551 ÷ 57.558
57.558 ÷ 57.565
57.565 ÷ 57.572
Play on fitting
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
0.046 ÷ 0.060
COUPLING BETWEEN PISTON AND CYLINDER (200)
Name
[p]
[p]
[p]
[p]
Initials
A
B
C
D
Cylinder
71.990 ÷ 71.997
71.997 ÷ 72.004
72.004 ÷ 72.011
72.011 ÷ 72.018
Piston
71.953 ÷ 71.960
71.960 ÷ 71.967
71.967 ÷ 71.974
71.974 ÷ 71.981
Play on fitting
0.030 - 0.044
0.030 - 0.044
0.030 - 0.044
0.030 - 0.044
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.10 ÷ 0.35
0.15 ÷ 0.30
Piston rings
SEALING RINGS (125)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring 1st
oversize
CHAR - 14
Description
Dimensions
57 x 1
57x1
57x2.5
57.2 x 1
Liberty 125 - 200 4tempi
Name
Oil scraper ring 1st
oversize
Oil scraper ring 1st
oversize
Compression ring 2nd
oversize
Oil scraper ring 2nd
oversize
Oil scraper ring 2nd
oversize
Compression ring 3rd
oversize
Oil scraper ring 3rd
oversize
Oil scraper ring 3rd
oversize
Description
Characteristics
Dimensions
57.2x1
Initials
A
Quantity
0.10 ÷ 0.30
57.2x2.5
A
0.10 ÷ 0.35
57.4x1
A
0.15 ÷ 0.30
57.4x1
A
0.10 ÷ 0.30
57.4x2.5
A
0.10 ÷ 0.35
57.6x1
A
0.15 ÷ 0.30
57.6x1
A
0.10 ÷ 0.30
57.6x2.5
A
0.10 ÷ 0.35
Initials
A
A
A
Quantity
0.15 ÷ 0.30
0.20 ÷ 0.40
0.20 ÷ 0.40
Maximum clearance after use: 1 mm
SEALING RINGS (200)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Description
Dimensions
72x1.5
72x1
72x2.5
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (125)
Name
Half-shaft, transmission
side
Flywheel-side half shaft
Connecting rod with PP
Crank pin width
Description
Dimensions
16,6 +0-0,05
Initials
A
Quantity
D = 0.20 ÷ 0.50
16,6 +0-0,05
18 -0.10 -0.15
51.400
B
C
E
D = 0.20 ÷ 0.50
0.20 ÷ 0.50
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS
(125)
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft category 1 Crankcase category 1
Crankshaft category 1 Crankcase category 2
Description
Dimensions
Initials
Category 1
Class 2
Category 1
Category 2
Category B - blue
Type C - yellow
Category E - green
E-E
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.953 ÷ 32.959
32.959 ÷ 32.965
1.973 ÷ 1.976
1.976 ÷ 1.979
1.979 ÷ 1.982
C-C
CHAR - 15
Liberty 125 - 200 4tempi
Characteristics
Name
Crankshaft category 2 Crankcase category 1
Crankshaft category 2 Crankcase category 2
Description
Dimensions
Initials
C-C
Quantity
B-B
Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (200)
Name
Half-shaft, transmission
side
Flywheel-side half shaft
Connecting rod with PP
Crank pin width
Description
Dimensions
16,6 +0-0,05
Initials
A
Quantity
D = 0.20 ÷ 0.50
16,6 +0-0,05
18 -0.10 -0.15
B
C
E
D = 0.20 ÷ 0.50
0.20 ÷ 0.50
51.4 +0.050
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS
(200)
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft half-bearing
Crankshaft category 1 Crankcase category 1
Crankshaft category 1 Crankcase category 2
Crankshaft category 2 Crankcase category 1
Crankshaft category 2 Crankcase category 2
Description
Crankshaft/crankcase axial clearance: 0.15 ÷ 0.43
CHAR - 16
Dimensions
Initials
Category 1
Class 2
Category 1
Class 2
Category B - blue
Type C - yellow
Category E - green
E-E
C-C
C-C
B-B
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.959 ÷ 32.965
32.953 ÷ 32.959
1.973 ÷ 1.976
1.976 ÷ 1.979
1.979 ÷ 1.982
Liberty 125 - 200 4tempi
Characteristics
Products
TABLE OF RECOMMENDED PRODUCTS
Product
AGIP ROTRA 80W-90
Description
rear hub oil
AGIP CITY HI TEC 4T
Oil to lubricate flexible transmissions
(brakes, throttle control and odometer)
Oil for air filter sponge
AGIP FILTER OIL
AGIP GP 330
AGIP CITY HI TEC 4T
AGIP GREASE MU3
Specifications
SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Oil for 4-stroke engines
Mineral oil with specific additives for increased adhesiveness
Grease (brake control levers, throttle
Calcium complex soap-based grease
grip)
with NLGI 2; ISO-L-XBCIB2
Engine oil
SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
Grease for odometer transmission gear Soap-based lithium grease with NLGI 3;
case
ISO-L-XBCHA3, DIN K3K-20
CHAR - 17
INDEX OF TOPICS
TOOLING
TOOL
Liberty 125 - 200 4tempi
Tooling
TOOLS
Stores code
001330Y
Description
Tool for fitting steering seats
001467Y009
Driver for OD 42-mm bearings
001467Y013
Pliers to extract ø 15-mm bearings
002465Y
Pliers for circlips
005095Y
Engine support
008564Y
Flywheel extractor
TOOL - 19
Liberty 125 - 200 4tempi
Tooling
TOOL - 20
Stores code
020004Y
Description
Punch for removing fifth wheels from
headstock
020055Y
Wrench for steering tube ring nut
020074Y
Support base for checking crankshaft
alignment
020150Y
Air heater support
020151Y
Air heater
020193Y
Oil pressure gauge
Liberty 125 - 200 4tempi
Tooling
Stores code
020262Y
Description
Crankcase splitting strip
020263Y
Driven pulley assembly sheath
020287Y
Clamp to assemble piston on cylinder
020306Y
Punch for assembling valve sealing rings
020329Y
MityVac vacuum-operated pump
020330Y
Stroboscopic light to check timing
TOOL - 21
Liberty 125 - 200 4tempi
Tooling
TOOL - 22
Stores code
020331Y
Description
Digital multimeter
020332Y
Digital rev counter
020333Y
Single battery charger
020334Y
Multiple battery charger
Liberty 125 - 200 4tempi
Tooling
Stores code
020335Y
Description
Magnetic support for dial gauge
020357Y
020359Y
32x35-mm Adaptor
42x47-mm Adaptor
020360Y
52x55-mm Adaptor
020363Y
20 mm guide
020364Y
25-mm guide
TOOL - 23
Liberty 125 - 200 4tempi
Tooling
TOOL - 24
Stores code
020368Y
Description
driving pulley lock wrench
020375Y
Adaptor 28 x 30 mm
020376Y
Adaptor handle
020382Y011
adapter for valve removal tool
020409Y
Multimeter adaptor - Peak voltage detection
Liberty 125 - 200 4tempi
Tooling
Stores code
020412Y
Description
15 mm guide
020414Y
28-mm guide
020423Y
Driven pulley lock wrench
020424Y
Driven pulley roller casing fitting punch
020425Y
Punch for flywheel-side oil seal
020426Y
Piston fitting fork
TOOL - 25
Liberty 125 - 200 4tempi
Tooling
TOOL - 26
Stores code
020427Y
Description
Piston fitting band
020428Y
Piston position check support
020430Y
Pin lock fitting tool
020431Y
Valve oil seal extractor
020434Y
Oil pressure control fitting
020444Y
Tool for fitting/ removing the driven pulley
clutch
Liberty 125 - 200 4tempi
Tooling
Stores code
020565Y
Description
Flywheel lock calliper spanner
020622Y
Transmission-side oil guard punch
494929Y
Exhaust fumes analyser
020625Y
Kit for sampling gas from the exhaust
manifold
TOOL - 27
INDEX OF TOPICS
MAINTENANCE
MAIN
Liberty 125 - 200 4tempi
Maintenance
Maintenance chart
EVERY 2 YEARS
Action
Brake fluid - change
EVERY 3000 KM
Action
Engine oil - level check/ top-up
AFTER 1000 KM
80'
Action
Engine oil - replacement
Hub oil - change
Oil filter (net filter) - clean
Idle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 6000 KM, 18000 KM, 54000 KM
150'
Action
Engine oil - replacement
Hub oil level - check
Spark plug electrode gap - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Variable speed rollers/pads - check
Driving belt - checking
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
AFTER 12000 KM, 60000 KM
160'
Action
Engine oil - replacement
Hub oil level - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
MAIN - 29
Liberty 125 - 200 4tempi
Maintenance
Action
Driving 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
Centre stand - lubrication
Secondary air filter - cleaning
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 24000 KM, 48000 KM
175'
Action
Engine oil - replacement
Hub oil - change
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Spark plug - replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Cylinder ventilation system - cleaning
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
Secondary air filter - cleaning
Centre stand - lubrication
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 30000 KM, 42000 KM, 66000 KM
95'
Action
Engine oil - replacement
Hub oil level - check
Spark plug electrode gap - check
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Slide pads and variator rollers - check
Driving belt - checking
Brake pads - check condition and wear
Brake fluid level - check
Electrical system and battery - check
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
MAIN - 30
Liberty 125 - 200 4tempi
Maintenance
AFTER 36000 KM
270'
Action
Engine oil - replacement
Hub oil - change
Spark plug - replacement
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Flexible brake tubes - replacement
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Secondary air filter - cleaning
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
AFTER 72,000 KM
270'
Action
Engine oil - replacement
Hub oil - change
Spark plug - replacement
Air filter - clean
Engine oil - change
Oil filter (net filter) - clean
Valve clearance - adjustment
Idle speed (*) - adjustment
Throttle lever - adjustment
Pads and variator rollers - replacement
Driving belt - replacement
Odometer gear - greasing
Steering - adjustment
Cylinder ventilation system - check
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Flexible brake tubes - replacement
Transmission elements - lubrication
Safety locks - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Secondary air filter - cleaning
Centre stand - lubrication
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See instructions in the «Idle speed adjustment» section
MAIN - 31
Maintenance
CO check
- Remove the exhaust gases outlet cap on the exhaust pipe
- Using the supplied washer, install the exhaust
gases collection kit fitting onto the pipe, as shown
in the figure.
- Correctly orientate the components as shown in
the picture
- Shut the gas outlet on the tool
- Start the engine and let it warm up
- Shut the engine down
- Disconnect the SAS check valve vacuum hose
shown in the figure.
- Seal the connection using a conical a cap.
- Connect the Mitivac vacuum pump to the SAS
control valve.
- Start the vacuum pump up to a pressure of -0.6
÷ -0.8 bar so to close the valve and cut off the SAS
system.
- Remove the exhaust gas collection kit cap and
connect the analyzer adequately pre-heated.
- Check the analyser output and the engine rpm.
- Adjust the CO concentration.
N.B.
MAIN - 32
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Maintenance
CHECK THAT THE RESULT IS OBTAINED WITH THE
VALVE GAS IN CLOSED POSITION.
N.B.
ALSO CHECK THE CARBURETION ADJUSTMENT IS OBTAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND
4 TURNS.
N.B.
OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN
THE TANK AND THE FUEL CIRCUIT.
N.B.
IN CASE OF UNSTABLE CO, CHECK THAT THE CARBURETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DEPRESSION SEALS WORK ADEQUATELY
N.B.
IN CASE OF 1000 PPM UNBURNED HYDROCARBONS
(HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST
VALVE TIGHTNESS.
Specific tooling
020329Y MityVac vacuum-operated pump
020332Y Digital rev counter
494929Y Exhaust fumes analyser
020625Y Kit for sampling gas from the exhaust
manifold
Characteristic
CO Check
3.8±0.7 to 1650±50 RPM
MAIN - 33
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Liberty 125 - 200 4tempi
Troubleshooting
Engine
Poor performance
POOR PERFORMANCE
Possible Cause
Air filter blocked or dirty.
Fuel nozzles or cock clogged or dirty
Dirty or faulty vacuum-operated cock
Failing automatic starter on the carburettor
Excessive driving belt wear
Lack of compression: parts, cylinder and valves worn
Oil level exceeds maximum
Excess of encrustations in the combustion chamber
Incorrect timing or worn timing system elements
Muffler obstructed
Inefficient automatic transmission
Wrong valve adjustment
Overheated valves
Valve seat distorted
Worn cylinder, Worn or broken piston rings
Operation
Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to
drip dry and then reassemble.
Dismantle, wash with solvent and dry with compressed air
Check the filter on the cock, remove the petrol and wash the
tank, if necessary. Replace the cock as a last resource.
Check the electrical wiring and mechanical movement, replace
if necessary.
Check it and replace, if necessary
Replace the worn parts
Check for causes and fill to reach the correct level
Descale the cylinder, the piston, the head and the valves
Time the system again or replace the worn parts
Replace
Check the rollers and the pulley movement, replace the damaged parts and lubricate the driven pulley moveable guide with
Montblanc Molybdenum Grease
Adjust the valve clearance properly
Remove the head and the valves, grind or replace the valves
Replace the head assembly
Replace the piston cylinder assembly or just the piston rings
Rear wheel spins at idle
REAR WHEEL ROTATES WITH ENGINE AT IDLE
Possible Cause
Idling rpms too high
Clutch fault
Operation
Adjust the engine idle speed and the CO%, if necessary.
Check the springs / clutch masses
Starting difficulties
DIFFICULTY STARTING UP
Possible Cause
Battery flat
Faulty spark plug or incorrect ignition advance
- Engine flooded.
Incorrect valve sealing or valve adjustment
Rpm too low at start-up or engine and start-up system damaged
Altered fuel characteristics
Vacuum operated cock failure
Operation
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
Replace the spark plug or check the ignition circuit components
Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the motor turn so as to expel the fuel excess taking care to
connect the cap to the spark plug, and this in turn to the ground.
If the fuel tank is empty, refuel and start up.
Inspect the head and/or restore the correct clearance
Check the starter motor and the kick-starter unit
Drain off the fuel no longer up to standard; then, refill
Check that fuel is adequately supplied through the pipe by applying a vacuum to the suction pipe
TROUBL - 35
Liberty 125 - 200 4tempi
Troubleshooting
Possible Cause
Failing automatic starter on the carburettor
Start-up enabling buttons failure
Carburettor nozzles clogged or dirty
Air filter obstructed or dirty.
Operation
Check the electrical wiring and mechanical movement, replace
if necessary.
Check continuity using an Ohm meter, with the switch pressed;
replace if necessary
Dismantle, wash with solvent and dry with compressed air
Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to
drip dry and then reassemble.
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST
Possible Cause
Worn valve guides
Worn valve oil guard
Oil leaks from the couplings or from the gaskets
Worn or broken piston rings or piston rings that have not been
fitted properly
Operation
Check and replace the head unit if required
Replace the valve oil guard
Check and replace the gaskets or restore the coupling seal
Replace the piston cylinder unit or just the piston rings
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE
Possible Cause
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Perform the dimensional checks on the oil pump components
Replace the cartridge filter
Restore the level using the recommended oil type (Selenia HI
Scooter 4 Tech)
Engine tends to cut-off at full throttle
THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE
Possible Cause
Maximum jet clogged
Water or condensate in the carburettor tank
Level in tank too low
Operation
Remove the carburettor, wash with solvent and dry with compressed air
Remove the tank, wash with solvent and dry with compressed
air
Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Engine tends to cut-off at idle
THE ENGINE TENDS TO STOP AT IDLE SPEED
Possible Cause
Incorrect idle adjustment
Incorrect timing
The starter remains on
Faulty spark plug or incorrect ignition advance
Pressure too low at the end of compression
Minimum nozzle dirty
TROUBL - 36
Operation
Adjust using the rpm indicator
Time the system and check the timing system components
Check: electric wiring, circuit not interrupted, mechanical
movement and power supply; replace if necessary
Replace the spark plug or check the ignition circuit components
Check the thermal group seals and replace worn components
Wash the nozzle with solvent and dry with compressed air
Liberty 125 - 200 4tempi
Troubleshooting
High fuel consumption
EXCESSIVE 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
Check the maximum and minimum nozzles are adequately
fixed in their fittings
Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Loose nozzles
Incorrect float level
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Slippage or irregular functioning
Operation
Check that there is no grease on the masses.
Check that the faying surface between the clutch masses and
the clutch bell is mainly in the middle and with equivalent specifications on the three masses.
Check that the clutch bell is not scored or worn abnormally
Never run the engine without the clutch bell
Insufficient braking
INEFFICIENT OR NOISY BRAKING
Possible Cause
Worn brake pads or shoes
Front brake disk loose or deformed
Air bubbles inside the hydraulic braking system
Fluid leakage in hydraulic braking system
Excessive backlash in the rear brake control cable
Operation
Replace the brake pads or shoes and check for brake disk or
drum wear conditions.
Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Carefully bleed the hydraulic braking system, (there must be
no flexible movement of the brake lever).
Failing elastic fittings, plunger or brake pump seals, replace
Adjust the backlash with the appropriate adjuster located on
the back part of the crankcase.
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Rubber gaskets swollen or stuck
Compensation holes on the pump clogged
Brake disc slack or distorted
Defective piston sliding
Operation
Replace gaskets.
Clean carefully and blast with compressed air
Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Check calliper and replace any damaged part.
TROUBL - 37
Liberty 125 - 200 4tempi
Troubleshooting
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.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING
Possible Cause
Electronic ignition device failure
Operation
With the key switch set to "ON" jump the contacts 1 (BlueBlack) and 5 (Orange) on the control unit connector.
If by operating the turn indicator control the lights are not steadily on, replace the control unit; otherwise, check the cable
harness and the switch.
Steering and suspensions
Heavy steering
STEERING HARDENING
Possible Cause
Steering hardening
Operation
Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: if they are recessed or if the balls are squashed, replace
them.
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
Excessive steering clearance
TROUBL - 38
Operation
Check the tightening of the top ring nut. 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.
Liberty 125 - 200 4tempi
Troubleshooting
Noisy suspension
NOISY SUSPENSION
Possible Cause
Noisy suspension
Operation
If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition.
Finally, check the locking torque of the wheel axle nut, the
brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber
work properly.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION
Possible Cause
Oil leakage from suspension
Operation
Replace the rear shock absorber or the front fork cartridge.
TROUBL - 39
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Liberty 125 - 200 4tempi
Electrical system
Legend:
1. Front LHS turn signal lights (2 bulbs for each lamp)
2. Immobiliser antenna
3. Electronic ignition device with integrated turn signal and choke controller.
4. Horn button
5. Turn signal switch
6. Light switch
7. Stop light switch on rear brake
8. Dual-setting light bulb 12V - 55/60W
9. Headlamp light bulb
10. High beam warning light
11. Low oil pressure warning light
12. Turn signal warning light (RHS)
ELE SYS - 41
Electrical system
Liberty 125 - 200 4tempi
13. Low fuel warning light
14. Turn signal warning light (LHS)
15. Dashboard light bulbs
16. Headlamp warning light
17. Odometer with warning lights and level gauges (7 and 2 light bulbs respectively)
18. Headlight
19. Two fuse holders with four fuses (7.5 A)
20. Front brake stop light switch
21. Starter button
22. Immobiliser diagnostic port
23. Key-switch
24. Front RHS turn signal light
25. Cable harness
26. Fuel level sender
27. Fuse holder assembly
28. Rear RHS turn signal light
29. License plate light bulb
30. License plate lamp
31. Battery
32. Starter relay
33. Starter motor
34. Low oil pressure sensor
35. Pick-up
36. Automatic choke device
37. Carburettor heater
38. H.T. coil
39. Taillight assembly
40. Stop and taillight bulb
41. Voltage regulator
42. Rear LHS turn signal light
43. Two amber bulbs for turn signal
44. Relay
45. Horn
Wires colour coding:
B = White
Bl = Blue
G = Yellow
Mr = Brown
ELE SYS - 42
Liberty 125 - 200 4tempi
Electrical system
N = Black
BV = White-Green
GN = Yellow-Black
Gr = Grey
Rs = Pink
R = Red
Vi = Purple
V = Green
VN = Green-Black
BN = White-Black
BBl = White-Blue
GV = Yellow-Green
Ar = Orange
Az = Light Blue
GrBl = Grey-Blue
GrN = Grey-Black
RBl = Red-Blue
GR =Yellow-Red
BlN = Blue-Black
Conceptual diagrams
Ignition
ELE SYS - 43
Liberty 125 - 200 4tempi
Electrical system
IGNITION
1
2
3
4
5
6
Specification
electronic control unit
Magneto flywheel
Pick - up
HV coil
Spark plug
Voltage regulator
Desc./Quantity
Headlights and automatic starter section
HEADLIGHTS AND AUTOMATIC STARTER SECTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
ELE SYS - 44
Specification
electronic control unit
Carburettor heater
Automatic starter
Key switch
Main fusible
Battery (125)
Battery (200)
Headlamp relay
Light switch
High-beam fuse
Low-beam and dashboard lights fuse
Low-beam light bulb
High-beam light bulb
High-beam lamp warning light
Front side-light bulb
Four dashboards illuminating bulbs
Taillight bulb
License plate bulb
Low-beam fuse
Desc./Quantity
15A
12V - 9Ah
12V - 12Ah
7,5A
7,5A
12V - 55W
12V-55W
12V - 1.2W
12V - 5W
12V - 1,2W
12V - 5W
12V - 5W
7,5A
Liberty 125 - 200 4tempi
Electrical system
Battery recharge and starting
BATTERY RECHARGE AND START-UP SECTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Specification
Magneto flywheel
Voltage regulator
Pick - up
Main fusible
Battery (125)
Battery (200)
Starter relay
Starter motor
Start up button
Front and rear brake light button
Brake light filament
Fuse
Key switch
electronic control unit
Desc./Quantity
15A
12V - 9Ah
12V - 12Ah
12V-21W
7.5 A
ELE SYS - 45
Liberty 125 - 200 4tempi
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
16
17
18
19
ELE SYS - 46
Specification
electronic control unit
Battery (200)
Battery (125)
Main fusible
Key switch
Engine oil pressure sensor
Low oil pressure warning light
Low fuel warning light
Fuel gauge
Fuel level sender
Fuse
Immobilizer aerial
Low engine oil pressure sensor
Immobiliser LED
Front and rear brake light button
Taillight bulb
Starter motor
Starter relay
Start up button
Desc./Quantity
12V - 12Ah
12V - 9Ah
15A
12V - 1,2W
12V - 1.2W
7.5 A
12V - 5W
Liberty 125 - 200 4tempi
Electrical system
Turn signal lights
TURN INDICATORS AND HORN
1
2
3
4
5
6
7
8
9
10
11
Specification
electronic control unit
Indicators switch
4 Turn indicator bulbs
Turn signal warning light bulbs
Main fusible
Battery (125)
Battery (200)
Horn
Fuse
Key switch
Horn button
Desc./Quantity
12V-10W
12V - 2W
15A
12V - 9Ah
12V - 12Ah
7.5 A
ELE SYS - 47
Liberty 125 - 200 4tempi
Electrical system
Instruments and warning lights control board
4-PIN CONNECTOR
Specification
Ground lead (-)
Left turn indicator
Right turn indicator
Contact not connected
1
2
3
4
Desc./Quantity
6-PIN CONNECTOR
1
2
3
4
5
6
Specification
Fuel gauge
High-beam warning light
Engine oil warning light
Fuse
Low fuel warning light
Instrument panel lighting and headlamp warning light
Checks and inspections
ELE SYS - 48
Desc./Quantity
7.5 A
12V - 1.2W
Liberty 125 - 200 4tempi
Electrical system
Immobiliser
The electric ignition system is fed with direct current and is protected by an antitheft immobilizer
integrated to the control unit.
The ignition system consists of:
- electronic control unit
- immobilizer aerial
- master and service keys with built-in transponder
- H.V. coil
- diagnosis LED
The diagnosis LED also works as a blinking light
to deter theft. This function is activated every time
the key switch is set to «OFF», when the side
stand is lowered or the engine emergency cut-off
switch is set to «OFF». It remains activated for 48
hours in order not to affect the battery charge.
When the ignition switch is turned to «ON», the
deterring blinker function is deactivated. Subsequently, a flash confirms the switching to « ON».
The duration of the flash depends on the electronic
control unit program (see figure).
Whenever the LED is off and remains so, even
when switching it to «ON», it is necessary to check
if:
- the battery is charged
- 15A main fuse is working correctly.
Connect the immobilizer tester to the diagnosis
socket (see ET4 125 manual) located behind the
front left fuse box flap.
If the serial LED remains off, check the electronic
control unit supply as follows:
ELE SYS - 49
Electrical system
Detach the connector from the ECU and check the
following:
- Presence of battery potential difference between
terminal 4 (Red/Blue) and earth
- Presence of battery potential difference between
terminals 4 (Red/Blue) and 8 (black), as shown in
the figure.
- Presence of battery potential difference between
terminals 5 and 8 with the key-switch onto «ON».
If no anomalies are found, replace the electronic
control unit.
Virgin circuit
If the ignition system has not been programmed,
the engine can be started but it will run limited to
2000 rpm. When trying to accelerate, some evident loss of power may be felt.
Program the system with the MASTER (Brown)
and SERVICE (Blue) keys as follows:
- Insert the MASTER key, turn it to "ON" and keep
it in that position for 2 seconds (limit values: 1 ÷ 3
seconds).
- Alternatively insert all the available black keys
and turn each one of them to "ON" for 2 seconds.
- Insert the MASTER key again and turn it to "ON"
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys (blue) can be programmed at one time.
Sequence and times must be strictly observed or
it will be necessary to repeat the procedure from
the start.
ELE SYS - 50
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Electrical system
Once the control unit has been programmed, the
control unit is inseparably matched with the MASTER key transponder.
This matching allows programming further service
keys in case of loss, replacement, etc. Each new
time new data is programmed the previously stored one is deleted.
If a service key setting is lost, it is essential to
carefully check the efficiency of the high voltage
system:
Shielded cap resistance ~ 5000 Ω.
In any case, it is advisable to use resistive spark
plugs as shown in the figure.
Diagnostic codes
The flash indicating the switching to "ON" (0.7-sec
flash) can be followed by a phase of programmed
failure warnings.
That is, the LED is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-sec flashes.
After the failure code indication, a steadily on LED
signals that ignition is disabled; see the table:
2-FLASH CODE
Example with programmed electronic control unit,
no transponder and/or aerial malfunction
Ignition disabled-Vehicle immobilised
3-FLASH CODE
Example with programmed electronic control unit,
aerial working properly and unknown transponder
code.
Ignition disabled-Vehicle immobilised
Diagnostic code - 2 flashes
When the 2-flash code is detected, carry out the following checks:
- Check if the failure continues even after changing key (including the MASTER key). If the failure
persists with any key, disconnect the aerial connector from the electronic control unit and check the
aerial continuity with the multimeter.
ELE SYS - 51
Electrical system
Liberty 125 - 200 4tempi
If it does not work, replace the aerial.
If no faults are found, replace the control unit.
CAUTION
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE
CODE IS INDICATED. THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY.
Specific tooling
020331Y Digital multimeter
Electric characteristic
Resistance value
~ 7 ÷ 9 Ohm
Diagnostic code - 3 flashes
If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the
key switch.
- If the failure disappears when the MASTER key is used, proceed with coding a new service key (Blue).
- If the failure persists, it means that the MASTER key and the control unit are not linked; in this case,
replace the control unit and then encode the keys.
The immobilizer system is efficient when, after switching over to «ON», only a 0.7-sec flash is detected
(see diagram).
In this case, the engine can be started.
Example with programmed control unit, transponder, programmed key and working aerial. The
ignition is enabled (regular use conditions)
Ignition circuit
All the control operations of the system that entail disconnecting cables (to check connections and the
devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls
might be irretrievably damaged.
The battery provides the basic power supply. The system is adjusted so that the start-up system immediately detects an eventual battery voltage drop, and this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; therefore, the control unit is connected
to the Pick-Up by the chassis and the engine ground lead.
ELE SYS - 52
Liberty 125 - 200 4tempi
Electrical system
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding is efficient.
No spark plug
When noticing no spark plug proceded as follows:
- Pick-Up inspection.
Detach the ECU connector and check for continuity between terminals 2 (Green) and 8 (Black).
The inspection must include the pick-up and it's
power cable.
If an open circuit is found, repeat the inspection
between the flywheel connector and earth. If unacceptable values are found, proceed by replacing
the pick-up, otherwise repair the cable.
Electric characteristic
Pick-up resistance value
Pick-up resistance value: 105 ÷ 124 Ohm
- H.T. coil primary circuit inspection
Detach the connector from the ECU and check for
continuity between terminals 3 (purple) and 8
(black) (see figure).
If unacceptable values are found, repeat the inspection directly from the positive and negative
terminals of the H.T. coil primary circuit.
If the values are within the prescribed limit, proceed by repairing the wiring or reattaching all wirings, otherwise replace the H.T. coil.
Electric characteristic
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4 ÷
0.5 Ohm
- HV coil secondary check
Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see figure).
If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis,
check the peak voltage with the multimeter adaptor.
Specific tooling
ELE SYS - 53
Electrical system
020409Y Multimeter adaptor - Peak voltage detection
Electric characteristic
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm
- Pick-Up
Detach the ECU connector and connect the positive terminal to connector no. 2 and the negative
terminal to connector no. 8 (see figure).
Crank the engine using the starter motor and
check the tension produced by the pick-up.
If unacceptable values are found, replace the PickUp.
N.B.
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Electric characteristic
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- H.V. coil
With the control unit and HV coil connected to the
circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor
and connect the positive terminal to the earth one
and the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS
BLACK.
Electric characteristic
High voltage coil voltage value
High voltage coil voltage value: > 100 Volt
ELE SYS - 54
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Electrical system
Battery recharge circuit
The recharge system is provided with a three phase alternator with permanent flywheel.
The alternator is directly connected to the voltage regulator.
In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety
fuse.
This system therefore requires no connection to the key switch.
The three- phase generator provides good recharge power and at low revs a good compromise is
achieved between generated power and idle stability.
For this reason, it is very important that the idle speed is adjusted as prescribed.
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any
yellow cable and the other two cables.
Electric characteristic
Ohm value:
0.7 ÷ 0.9 Ohm
Also check that all yellow cables are insulated from
the ground connection.
If non-conforming values are detected, repeat the
checks directly to the stator. In case of further repetitions of incorrect values replace the stator or
repair the wiring.
ELE SYS - 55
Electrical system
Voltage regulator check
With a perfectly charged battery and lights off,
measure voltage at the battery poles with a high
running engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
Recharge system voltage check
Connect an ammeter induction clamp to the voltage regulator positive terminal, measure the battery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current generated by the system with lights on and a high
running engine.
In case the generated current value is lower than
8A, repeat the test using a new regulator and/stator alternatively.
Choke Inspection
Refer to the engine section to check the resistance
and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals
receive battery voltage when the engine is on
(see figure).
If no voltage is detected, connect the multimeter
negative terminal to the ground lead and the positive terminal to the automatic starter orange cable;
ELE SYS - 56
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Electrical system
with the key switch set to "ON" check whether
there is battery voltage; if there is no voltage,
check the wiring connections to the key switch.
If battery potential is found, repeat the inspection
from the connector to the ECU.
After detaching the choke device, start the engine
and, while at idle, check for tension connecting the
positive terminal of the multimetre to terminal 5
(Orange) and the negative to terminal 7 (White/
Black) (see figure).
If no tension is found, replace the ECU; otherwise
check the wiring between the choke device and the
ECU.
Turn signals system check
- If the turn signal lights are faulty, proceed as follows:
- Detach the ECU connector and check for battery
tension between terminal 5 (Orange) and earth,
with the key-switch onto «ON».
- Check the same is present between terminals 5
(Orange) and 8 (Black).
If no tension is measured, check the wiring, otherwise proceed as follows:
- Jumper terminals 1 (Black/Blue) and 5 (Orange),
see figure, and alternately operate the turn signal
switch towards left and right wit the key-switch onto «ON» and check the bulbs go off.
If this happens, replace the ECU, as faulty.
If this does not happen, check the wiring between
the ECU and the turn signal switch, hence repeat
the test.
ELE SYS - 57
Electrical system
Liberty 125 - 200 4tempi
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
Dry-charge battery
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.
ELE SYS - 58
Liberty 125 - 200 4tempi
Electrical system
Commissioning dry-charged batteries :
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 Be 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 using
the specific battery charger (single) or (multiple) at
a density of about 1/10 of the battery nominal capacity until fully charged; check that the acid density is about 27, corresponding to 31 Be, and that
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 on the vehicle ensuring
that it is wired up properly.
1 Hold the vertical tube
2 Look at the level
3 The float must be freed
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
Battery maintenance
The battery is an electrical device which requires careful monitoring and careful maintenance. The
maintenance rules are:
1) Electrolyte level check
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 electrical
system: the battery works overcharged and is subject to quick wear.
2)Load status check
ELE SYS - 59
Electrical system
Liberty 125 - 200 4tempi
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.
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 ground wire (black) marked
(-) must be connected to the -negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the +positive sign.
3) Recharging the battery
Remove the battery from the vehicle removing the negative clamp first.
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) Battery cleaning
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 SPARKS
AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR
THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
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
ELE SYS - 60
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
Exhaust assy. Removal
- Remove the 2 fixing nuts from the manifold to the
head
- Undo the 2 screws fixing the muffler to the housing; then remove the whole muffler paying attention to the interference between its supporting
bracket and the cooling cover.
Removal of the engine from the vehicle
•
Remove the spark plug access cover.
•
Remove the helmet compartment.
•
Remove the entire muffler assembly.
•
Disconnect the spark plug cap.
•
Remove the 3 screws on the transmission cover fixing the rear brake transmission.
•
Cut the fixing clamp and disconnect the
transmission air pipe. Disconnect the
engine ground lead after having unscrewed the specific screw on the cover.
ENG VE - 62
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
•
Engine from vehicle
Detach the electrical connections from
starter motor, choke device, carburettor heater and flywheel magneto.
•
Detach the throttle cable and the fuel
hose from the carburettor.
•
Detach the vacuum tube from the fuel
tap on the intake manifold.
•
Remove the rear shock absorber by
loosening the top and bottom fixings.
•
Loosen the engine-swingarm fixing nut
from the right hand side of the vehicle
and then remove the bolt from the left.
WARNING
BE VERY CAREFUL WHEN HANDLING FUEL.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.
See also
Helmet bay
Exhaust assy. Removal
ENG VE - 63
INDEX OF TOPICS
ENGINE
ENG
Liberty 125 - 200 4tempi
Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary
to remove the rear plastic cover first by inserting a
screwdriver in the corresponding slotted holes.
Using the clutch bell lock wrench, remove the driven pulley axle locking nut and recover the washer.
- Remove the cap/dipstick from the engine oil filling
hole.
- Remove the 10 screws and the earth cable fastened under one of them.
- Remove the transmission cover. If this operation
is performed directly on the vehicle, it is necessary
to remove the cooling air coupling and the three air
filter housing retainers.
Specific tooling
020423Y Driven pulley lock wrench
Air duct
- Unscrew the Torx screws fixing the air manifold
bulkhead and remove the bulkhead.
- Remove the 3 screws, then take out the manifold
as well as the filter.
ENG - 65
Engine
Air duct filter
- Unscrew the 2 fixing screws and slide off the filter.
- Clean with water and milid soap.
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.
- Use the specific tools to remove the bearing from
the crankcase.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
ENG - 66
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Refitting the driven pulley shaft bearing
- Heat up the crankcase inside with the hot air gun.
- Insert the bearing in its housing, refit the Seeger
ring.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020357Y 32x35-mm Adaptor
020412Y 15 mm guide
Removing the driven pulley
- Remove the spacer, the clutch bell and the whole
driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
ENG - 67
Engine
Checking the bell working surface eccentricity
- Install the bell on a driven pulley shaft using 2
bearings (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft unit on the support to check
the crankshaft alignment.
- Using a feeler pin gauge and the magnetic base,
measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central,
internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft
alignment
020335Y Magnetic support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
Removing the clutch
- By means of a calliper spanner, block the clutch
assembly rotation. - With a 46 mm spanner remove the clutch lock nut. - Remove the clutch and
the spring.
CAUTION
UPON REMOVING THE CLUTCH ASSEMBLY LOCK NUT,
PAY ATTENTION TO KEEP THE ASSEMBLY IN ITS SEAT
SO THAT IT DOES NOT COME OUT DUE TO THE SPRING
THRUST
Specific tooling
020565Y Flywheel lock calliper spanner
ENG - 68
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Prepare the locking tool for the driven pulley with
the pins half-screwed in the tool set to «C».
- Fit the driven pulley unit in the tool so as the bolt
get into the masses clutch support holes. Afterwards make the support screw make contact with
a minimum force.
- Using the specific wrench, inserted 46 mm from
the side, remove the clutch central locking nut.
- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE
TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE
SPECIFIC TOOL.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
020444Y009 wrench 46 x 55
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
ENG - 69
Engine
1 mm
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
- Remove the 3 guide pins and the movable halfpulley.
Removing the driven half-pulley bearing
- Remove the retaining ring using two flat blade
screwdrivers.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Remove the roller bearing using the specific extractor.
N.B.
REST THE HALF-PULLEY ON A WOOD SURFACE TO
AVOID DAMAGING THE THREADED RINGLET OF THE
DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide
ENG - 70
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Inspecting the driven fixed half-pulley
- Measure the external diameter of the pulley bushing.
Characteristic
Minimum diameter permitted
Ø 40.96 mm
Standard diameter
Ø 40.965 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
Minimum admissible diameter
Ø 41.08 mm
Standard diameter
Ø 41.035 mm
Refitting the driven half-pulley bearing
- Assemble a new roller case using the specific
punch, fit the bearing with the label facing outward
and insert it completely up to the punch on the halfpulley.
N.B.
REST THE HALF-PULLEY ON A WOOD SURFACE TO
AVOID DAMAGING THE THREADED RINGLET OF THE
DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020424Y Driven pulley roller casing fitting
punch
ENG - 71
Engine
- To assemble the new ball bearing insert it completely down in its housing with the specific punch
and finally assemble the Seeger ring.
Specific tooling
020375Y Adaptor 28 x 30 mm
020376Y Adaptor handle
020439Y 17 mm guide
Refitting the driven pulley
- Check that the faying surfaces between the 2
half-pulleys and the belt do not show any signs of
wear, scoring and grease.
- Insert the new oil seals and O-rings on the movable half-pulley.
- Assemble the half-pulley on the ringlet with the
appropriate protection sheath.
- 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 operation is necessary to avoid
the presence of grease beyond the O-rings.
Specific tooling
020263Y Driven pulley assembly sheath
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
ENG - 72
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Inspecting the clutch spring
- Measure the unloaded length of the spring of the
movable driven half-pulley.
Characteristic
Standard length:
106 mm
Refitting the clutch
Version 200
- Check the thickness of the clutch mass friction
material.
-The masses must not show traces of lubricants;
otherwise, check the driven pulley unit.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN
CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS SO AS TO
PREVENT A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
Minimum thickness permitted:
1 mm
- Support the driven pulley spring compressor appropriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring 11 with the chamfering
facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
ENG - 73
Engine
- Insert the driving belt into the pulley unit according to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
- Loosen the tool clamp and insert the belt according to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 wrench 46 x 55
Locking torques (N*m)
Nut locking clutch unit on pulley 55 ÷ 60 Nm
Version 125
ENG - 74
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Refit the clutch assembly following the fitting operation but in reverse order and using the calliper
spanner. Lock the nut to the specified torque.
CAUTION
USE A BOX-SPANNER WITH SMALL CHAMFER SO AS
NOT TO DAMAGE THE CLUTCH NUT.UPON FITTING THE
CLUTCH ASSEMBLY LOCK NUT, PAY ATTENTION TO
KEEP THE ASSEMBLY IN ITS SEAT UNTIL SOME NUT
THREADS HOLD IT IN PLACE
Locking torques (N*m)
Locking torque 55 ÷ 60 Nm
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
Drive-belt
During the wear checks foreseen in the scheduled
maintenance services at 6,000 km; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
- Check that the driving belt is not damaged.
- Check the width of the belt.
VERSION 125
Specification
Minimum width
Standard width
Desc./Quantity
21.5 mm
22.5 ± 0.2 mm
ENG - 75
Liberty 125 - 200 4tempi
Engine
VERSION 200
Specification
Minimum width
Standard width
Desc./Quantity
21±0.2 mm
22±0.2 mm
Removing the driving pulley
Driving pulley removal
- With the appropriate tool placed into the internal slots, remove the nut with the built-in Belleville washer.
Appropriate tools:
Specific tooling
020442Y Pulley lock wrench
- Remove the entire start-up crown unit with the
torque limiter.
- Remove the fixed driving half-pulley together with
the O-ring and the steel washer touching the bushing.
ENG - 76
Liberty 125 - 200 4tempi
Engine
- Lock the driving pulley with the specific tool as
shown in the figure. - Disassemble the central nut
and the Belleville washer, remove the drive and
the 2 washers. - Remove the stationary half pulley
and the steel washer.
Specific tooling
020368Y driving pulley lock wrench
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide pads.
Inspecting the rollers case
- Check that the internal bushing is not abnormally worn and measure inner diameter.
N.B.
DO NOT LUBRICATE OR CLEAN THE BUSHING.
BUSHING ROLLER CONTAINER
Specification
Maximum allowable diameter
Standard diameter
Desc./Quantity
Ø 26.121 mm
Ø 26+0 +0.021 mm
BUSH SLIDE PULLEY
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 25.950 mm
Ø 26-0.020 -0.041 mm
VARIABLE SPEED ROLLERS
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 18.5 mm
Ø 26±0.1 mm
ENG - 77
Engine
- Check the guide shoes for the variator back-plate
are not worn.
- Check there is no wear in the roller housing, and
the surfaces in contact with the belt on either of the
pulley halves.
- Pre-assemble the movable half-pulley with the
roller contrast plate by placing the rollers as shown
in the figure, that is, during insertion, the closed
side should be on the left side of the pulley thrust.
- Mount the complete bushing unit on the driving
shaft.
- Open the rear pulley and insert the belt observing
the correct direction of rotation.
WARNING
IT IS MOST IMPORTANT THAT WHEN FITTING THE FRONT
PULLEY UNIT, THE BELT IS FREE INSIDE SO AS TO AVOID
A WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.
ENG - 78
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Refitting the driving pulley
- Correctly reassemble the previously removed
Bendix back to its position.
- Fit the steel shim washer in contact with the
bushing and the fixed driving pulley together with
the O-ring on the outside of the fan blades.
- Fit the entire start-up crown assembly with the
torque limiter.
- Fit the torque limiter on the crankshaft so as to
guarantee the references on the start-up crown
and the fixed driving half-pulley are aligned. In
case this is not possible, choose the closest position to the references.
- Failure to do this may affect the cooling fan performance
The lock wrench operates on the start-up crown.
- If the torque limiter is worn, the failure can be detected when locking the nut on the crankshaft.
- The torque limiter cannot be serviced.
- In case of failures, replace the start-up crown and
the limiter.
Specific tooling
020442Y Pulley lock wrench
Recommended products
Loctite "Super Rapido" Loctite "Super Rapido"
243
Apply Loctite "Super Rapido" 243 on the threads
and screw the nut with washer to the prescribed
torque.
Locking torques (N*m)
Drive pulley nut 75 ÷ 83
ENG - 79
Engine
- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread threadlock on the thread and screw the nut
to the prescribed torque.
-Avoid the half-pulley rotation using a calliper
spanner
N.B.
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
Specific tooling
020368Y driving pulley lock wrench
Recommended products
Loctite 243 Medium-strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Locking torque 75 ÷ 83
Refitting the transmission cover
- Check that there are 2 centring dowels and that
the sealing gasket for the oil sump on the transmission cover is adequately fitted.
- Replace the cover and tighten the 10 screws to
the specified torque.
- Refit the oil loading cap/bar.
- Refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Refit the plastic cover.
Specific tooling
020423Y Driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60
End gear
ENG - 80
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Removing the hub cover
- Empty the rear hub through the oil drainage tap
located inside the hub cover
- Remove the brake shoe and relevant spring
- Remove the 7 flanged screws as shown in the
figure.
- Remove the rubber cover and the brake pad lever
sliding unscrewing the relevant retaining screw to
reach the rear of the cover
- Take off the hub cover and relevant gaskets
Removing the wheel axle
Remove the intermediate gear and the complete
hub cover.
Removing the hub bearings
- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are detected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y009 Driver for OD 42-mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
ENG - 81
Engine
Liberty 125 - 200 4tempi
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Remove the bearing with the adequate tools adequately supporting the hub cover, as shown in the
figure.
Specific tooling
020376Y Adaptor handle
020364Y 25-mm guide
With the appropriate tools, remove the oil seal as
shown in the figure.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm Adaptor
Removing the driven pulley shaft bearing
If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven
pulley.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.
- Remove the seeger ring shown in the figure
With the sectional punch, remove the driven pulley
shaft bearing.
Specific tooling
020376Y Adaptor handle
020375Y Adaptor 28 x 30 mm
020363Y 20 mm guide
See also
Removing the driven pulley
ENG - 82
Liberty 125 - 200 4tempi
Engine
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.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the
brake camshaft. - If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Heat up the parts using the specific heat gun
Specific tooling
020150Y Air heater support
020151Y Air heater
- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
- Refit the Seeger ring with the opening facing the
bearing as shown in the figure and fit a new oil
guard flush with the crankcase.
Refitting the wheel axle bearing
- Heat up the parts using the specific heat gun
Specific tooling
ENG - 83
Liberty 125 - 200 4tempi
Engine
020151Y Air heater
020150Y Air heater support
-The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide
020360Y 52x55-mm Adaptor
020376Y Adaptor handle
•
Assemble the Seeger ring.
•
Assemble the oil seal flush with the internal surface as shown in the figure to
the hub using the adequate tools and
with the seal lip towards the inside of
the hub.
Specific tooling
020376Y Adaptor handle
020360Y 52x55-mm Adaptor
Refitting the hub cover bearings
- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the
specific heat gun.
Specific tooling
020150Y Air heater support
020151Y Air heater
- The three 15 mm bearings must be fitted using
the appropriate tools.
ENG - 84
Liberty 125 - 200 4tempi
Engine
Refitting the hub bearings
- Insert the cover prepared in the crankcase taking
care of inserting the gear of the pulley shaft on the
intermediary gear.
Refitting the ub cover
- Fit a new gasket together with the centring dowels.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Screw the 7 screws to the specified torque, positioning the support plate of the pipe in the position shown in the figure.
- Remove the control pin of the shoe taking care
so as the long tooth coincides with the groove on
the control lever.
Locking torques (N*m)
Locking torque 24 ÷ 27
Flywheel cover
Cooling hood
-Remove the housing acting on the 4 retaining
screws.
CAUTION
DURING REMOVAL SLIDE THE HOUSING CONNECTOR
ON THE HOUSING.
ENG - 85
Engine
Liberty 125 - 200 4tempi
- Loosen the clamp and remove the carburettor
from the manifold.
-Remove the complete manifold acting on the 2
retainers as shown in the figure.
- Remove the 2 self threading screws, left and right
and the lateral base retaining screw on the crankcase base.
- Take off the housings.
- Remove the gasket seal of the housing on the
head.
N.B.
IF THE FLYWHEEL HOUSING IS NOT REMOVED, IT IS ALSO NECESSARY TO REMOVE THE TWO KNOB SCREWS.
On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest
to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.4 mm to 1.5
mm. Remember that such operation must have performed on a disassembled manifold which must be
cleaned afterwards.
Cooling fan
- Refit the parts in reverse order of the removal
operation.
- Make sure that there are spacers with the two
rear retainers of the housing.
- The long spacers should be in a high position.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR.
- Remove the cooling fan by acting on the three
fixings indicated in the figure.
ENG - 86
Liberty 125 - 200 4tempi
Engine
Removing the stator
- Remove the electric terminal of the minimum oil
pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
- Place the cable harness as shown in the figure.
N.B.
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE PIN AS
SHOWN IN THE DETAIL DRAWING.
Locking torques (N*m)
Stator screw 3 ÷ 4
Flywheel and starting
ENG - 87
Engine
Liberty 125 - 200 4tempi
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
Specific tooling
020565Y Flywheel lock calliper spanner
- Extract the flywheel with the extractor.
Specific tooling
008564Y Flywheel extractor
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key
properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
N.B.
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED
Locking torques (N*m)
Flywheel nut 52 ÷ 58
ENG - 88
Liberty 125 - 200 4tempi
Engine
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 motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the timing system drive
- Remove the parts listed below first: transmission
cover, belt driving pulley, oil pump pulley cover and
pinion separator washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve
lifter assembly and the automatic valve lifter assembly and its end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
ENG - 89
Engine
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft command pulley and its
washer.
- Remove the command sprocket wheel and the
timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner pad.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
See also
Removal
Transmission cover
Removing the driving pulley
Removing the cam shaft
- Remove the two screws and the cam shaft retainer shown in the diagram.
- Remove the cam shaft.
ENG - 90
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Remove the pin of the rocking levers from the
flywheel side holes.
- Remove the rocking levers and the elastic washer.
N.B.
MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO
AS TO AVOID THE INVERSION OF INLET WITH THE OUTLET.
Removing the cylinder head
- Remove the spark plug.
- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two centring dowels and
the gasket.
N.B.
IN NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKING LEVER PINS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN
TIGHTENER.
Removing the valves
- Using the specific tool fitted with the element
shown in the figure, remove the cotters, the plates
and the spring between the valves.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
ENG - 91
Engine
- Remove the oil seals with the appropriate tool.
- Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
Removing the cylinder - piston assy.
- Remove the chain guide pad.
- Remove the cylinder base gasket.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE
REMOVING THE CYLINDER.
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the 3 piston rings from the piston.
N.B.
BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
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 check-up: Maximum diameter
15.030 mm
ENG - 92
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Rod small end check-up: Standard diameter
15+0.015+0.025 mm
Inspecting the wrist pin
- Check the outer diameter of the gudgeon pin.
Characteristic
Standard pin diameter
14.996 ÷ 15 mm
Minimum diameter permitted
Ø 14.994 mm
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
Characteristic
Piston pin bore - standard diameter
Ø 15+0.001 +0.006
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Measure 36.5 mm from the piston crown's shown
in the figure.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
ENG - 93
Liberty 125 - 200 4tempi
Engine
Maximum allowable run-out:
0.05 mm
- The cylinder rectifying operation should be carried out with a surfacing that respects the original
angle.
- The cylinder surface roughness should be 0.9
micron.
- This is indispensable for a good seating of the
sealing rings, which in turn minimises oil consumption and guarantees optimum performance.
- The pistons are oversized due to cylinder rectification and are subdivided into three categories
1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They
are also classified into 4 categories A-A, B-B, CC, D-D.
Inspecting the piston
- Carefully clean the seal housings.
- Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as
shown in the diagram.
- If the clearance is greater than that indicated in the table, replace the piston.
STANDARD COUPLING CLEARANCE
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
0.025 ÷ 0.070
0.015 ÷ 0.060
0.015 ÷ 0.060
Initials
Quantity
MAXIMUM ADMITTED CLEARANCE AFTER USE
Name
Top piston ring
Middle piston ring
oil scraper
ENG - 94
Description
Dimensions
0.080 mm
0.070 mm
0.070 mm
Initials
Quantity
Liberty 125 - 200 4tempi
Engine
Inspecting the piston rings
- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis.
- Measure the opening, see figure, of the sealing rings using a thickness gauge.
- If any measurements are greater than specified, replace the piston rings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN
THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE
CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH
A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
SEALING RINGS (125)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring 1st
oversize
Oil scraper ring 1st
oversize
Oil scraper ring 1st
oversize
Compression ring 2nd
oversize
Oil scraper ring 2nd
oversize
Oil scraper ring 2nd
oversize
Compression ring 3rd
oversize
Oil scraper ring 3rd
oversize
Oil scraper ring 3rd
oversize
Description
Dimensions
57 x 1
57x1
57x2.5
57.2 x 1
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.10 ÷ 0.35
0.15 ÷ 0.30
57.2x1
A
0.10 ÷ 0.30
57.2x2.5
A
0.10 ÷ 0.35
57.4x1
A
0.15 ÷ 0.30
57.4x1
A
0.10 ÷ 0.30
57.4x2.5
A
0.10 ÷ 0.35
57.6x1
A
0.15 ÷ 0.30
57.6x1
A
0.10 ÷ 0.30
57.6x2.5
A
0.10 ÷ 0.35
Initials
Quantity
Initials
A
A
A
Quantity
0.15 ÷ 0.30
0.20 ÷ 0.40
0.20 ÷ 0.40
Initials
Quantity
Maximum clearance after use: 1 mm
MAX. VALUE (125)
Name
Top piston ring
Middle piston ring
Oil scraper
Description
Dimensions
0,40
0,40
0,45
SEALING RINGS (200)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Description
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
72x1.5
72x1
72x2.5
MAX. VALUE (200)
Dimensions
0,40
0,50
0,50
ENG - 95
Engine
Liberty 125 - 200 4tempi
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
- Fit the pin stop ring onto the appropriate tool.
Specific tooling
020430Y Pin lock fitting tool
- With the opening in position indicated on the tool,
take stop ring in the closed position using the
punch.
- Fit the wrist pin stop using the plug as shown in
the figure
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE
USED MANUALLY.
CAUTION
USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool
- Set the dial gauge to zero at a contrast plane with an average precharge, for example 5 mm. Keeping
the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.
- Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation)
- Calculate the difference between the two measurements: use the chart below to identify the thickness
of the cylinder base gasket to be used for refitting. The proper identification of the cylinder base gasket
thickness allows maintaining the correct compression ratio.
- Remove the special tool and the cylinder.
ENG - 96
Liberty 125 - 200 4tempi
Engine
Characteristic
Standard compression ratio
10.6 ± 0.5
CYLINDER BASE GASKET THICKNESS
Specification
Value measured
Thickness
Value measured
Thickness
Value measured
Thickness
Desc./Quantity
1 ÷ 1.1
0.8 ± 0.05
1.1 ÷ 1.3
0.6 ± 0.05
1.3 ÷ 1.4
0.4 ± 0.05
ENG - 97
Engine
Refitting the piston rings
- Place the oil scraper spring on the piston.
- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the crown of the piston.
The tapered side of the middle piston ring should
always be facing away from the crown of the piston.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'top' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
N.B.
SO AS TO OBTAIN THE BEST CONFIGURATION THE 2
SEALING RINGS ARE MADE WITH A CONTACT CONICAL
CYLINDER SECTION.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness
determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.
Specific tooling
020426Y Piston fitting fork
ENG - 98
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
020427Y Piston fitting band
Inspecting the cylinder head
- Using a trued bar check that the cylinder head
surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
Maximum admitted unevenness: Head check
0.05 mm
STANDARD DIAMETER
Specification
Standard diameter
Standard diameter
Standard diameter
Desc./Quantity
A Ø 32.5 ÷ 32.525
B Ø 20 ÷ 20.021
C Ø 12 ÷ 12.018
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft drive pulley, the chain
assembly and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts. if the
chain, pinion or pulley are worn, replace the whole
assembly.
ENG - 99
Liberty 125 - 200 4tempi
Engine
- Remove the central screw and the tensioner
spring. Check that the one-way mechanism is not
worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Inspecting the valve sealings
- Measure the width of the sealing surface on the valve seats.
VALVE SEAL SURFACE
Specification
Inlet valve - seal surface
Outlet valve - seal surface
Desc./Quantity
2.4 ÷ 2.8 mm
2.2 ÷ 2.6 mm
Inspecting the valve housings
- Remove any carbon formation from the valve guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights in the rocker arm push direction.
Characteristic
Standard drainage guide diameter
5.012 mm
Standard inlet guide diameter
5.012 mm
ENG - 100
Liberty 125 - 200 4tempi
Engine
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the specified limits, replace the cylinder head.
- Check width of the impression on the valve seat
«V»
Characteristic
Wear limits:
Max. 1.6 mm.
Inspecting the valves
- Measure the diameter of the valve stems in the
three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
Characteristic
Minimum diameter admitted - Inlet:
4.96 mm
Minimum diameter admitted - Outlet:
4.95 mm
Standard clearance - Inlet:
0.013 ÷ 0.040 mm
Standard clearance - Outlet:
0.025 ÷ 0.052 mm
Maximum clearance admitted- Inlet:
0.062 mm
Maximum clearance admitted - Outlet:
0.072 mm
- Check that there are no signs of wear on the
contact surface with the articulated register terminal.
- If the sealing surface on the valves is wider than
the specified limit, damaged in one or more points
or curved, replace the valve with a new one.
Characteristic
Standard valve length - Inlet:
80.6 mm
Valve standard length: drainage
ENG - 101
Engine
79.6 mm
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During
grinding, keep the cylinder head in a horizontal
position. This will prevent the lapping compound
residues from penetrating between the valve stem/
guide coupling.
CAUTION
TO AVOID SCORING THE CONTACT SURFACE, DO NOT
KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER
HEAD AND THE VALVES WITH A SUITABLE PRODUCT
FOR THE TYPE OF LAPPING COMPOUND BEING USED.
- Insert the valves into the cylinder head.
- Test the 2 valves alternatively.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter
halves show no signs of abnormal wear.
- Check the length clearance of the springs.
Characteristic
Valve spring length
33.9 ÷ 34.4 mm
ENG - 102
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Refitting the valves
- Lubricate the valve guides with engine oil.
- Place the lower plates of the valve spring on the
head.
- Use the punch to fit the 2 sealing rings one at a
time.
Specific tooling
020306Y Punch for assembling valve sealing
rings
- Fit the valves, the springs and the spring retaining
caps. Using the appropriate tool with adapter 11,
compress the springs and insert the cotters in their
seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y011 adapter for valve removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear
on the cams.
Characteristic
Standard diameter Bearing A
Ø: 32.5 mm -0.025 -0.050 mm
Standard diameter Bearing B
20 -0.020 -0.041 mm
Minimum admitted diameter bearing A
Ø: 32.440 mm
Minimum admitted diameter bearing B
Ø: 19.950 mm
Inlet cam height
27.512 mm
Outlet cam height
27.212 mm
ENG - 103
Engine
Liberty 125 - 200 4tempi
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
Characteristic
Maximum axial clearance admitted
0.42 mm
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check there are no signs of scoring or wear on
the rocking lever bolt.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
- Measure the internal diameter of each rocking
lever.
-Check that the elastic washer dedicated to the
axle clearance of the rocking levers is not worn. In case of anomalies, replace the damaged components.
Characteristic
Minimum diameter permitted
Ø 11.970 mm
Maximum diameter admitted
Ø 12.030 mm
Refitting the head and timing system components
- Fit the timing chain guide pad.
- Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder.
ENG - 104
Liberty 125 - 200 4tempi
Engine
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
Locking torques (N*m)
Locking torque 28 ÷ 30
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the tensioner pad by the cylinder head.
- Fit the spacer and the screw fastener.
- Fit the pin, the outlet rocking lever, the spring
washer and the inlet rocking lever.
- Lubricate the 2 rocking levers through the holes
at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams opposing the
rocking levers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
ENG - 105
Engine
Liberty 125 - 200 4tempi
- Refit the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head.
- Fit the pulley onto the camshaft.
- Assemble the counterweight with the corresponding fixing screw and tighten to the specified
torque.
Locking torques (N*m)
Locking torque 7 ÷ 8.5
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
cam shaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
approximately 180°.
N.B.
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed torque.
Locking torques (N*m)
Locking torque 12 - 14
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed
torque.
ENG - 106
Liberty 125 - 200 4tempi
Engine
Locking torques (N*m)
Locking torque 11 ÷ 13
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed
torque.
Locking torques (N*m)
Locking torque 5 - 6
- Adjust the valve clearance.
- Fit the spark plug
Electric characteristic
Recommended spark plug:
CHAMPION RG4HC
Electrode gap
0.8 mm
Locking torques (N*m)
Locking torque 12 - 14
- Assemble the casing sealing gasket on the head.
On the fitting direction, use the supplements on the
timing side as reference.
- Assemble the screw fixing the housing to the
crankcase to the specified torque and the 2 selfthreading screws joining the half-shells.
- Take care that the gasket is well inserted in its
housing during the assembly stage.
- Place the spark plug access cap.
Locking torques (N*m)
Locking torque 3 ÷ 4
- Fit the inlet manifold and lock the 2 screws to the
specified torque.
- Fit the carburettor onto the inlet manifold and lock
the clamp
N.B.
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT
ON THE MANIFOLD.
Locking torques (N*m)
Locking torque 11 ÷ 13
ENG - 107
Engine
- Refit the cylinder head cover, tightening the 4
clamping screws to the prescribed torque.
- Refit the fan and the housing.
- Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as
described in the lubrication chapter.
- Reassemble the driving pulley, the belt and the
transmission cover as described in the transmission chapter.
Locking torques (N*m)
Locking torque 11 ÷ 13
Crankcase - crankshaft
- Precautionary remove the following units:
transmission cover, driving pulley, driven pulley
and belt, rear hub cover, gears, bearings and oil
seals as described in the transmission chapter.
- Remove the oil sump, the by-pass, the chain
compartment cover and the oil pump as in the lubrication chapter.
- Remove the flywheel cover, the fan, the flywheel
and the stator as described in the magneto flywheel chapter.
- Remove the oil filter and the oil pressure bulb.
- Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter.
- Remove the 2 retainers indicated in the figure
and the starter motor.
- Before opening the crankcase, it is advisable to
check the axial clearance of the crankshaft. To do
this, use a plate and a support with specific tool
dial gauge.
Specific tooling
020262Y Crankcase splitting strip
020335Y Magnetic support for dial gauge
Characteristic
Standard clearance
ENG - 108
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
0.15 ÷ 0.40 mm
Splitting the crankcase halves
Remove the 11 coupling screws to the crankcase.
- Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase.
Remove the crankshaft.
CAUTION
IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.
- Remove the coupling gasket of the crankcase
halves.
- Remove the two screws and the internal cover
shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance
0.20 ÷ 0.50 mm
ENG - 109
Liberty 125 - 200 4tempi
Engine
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
CAUTION
BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard clearance
0.036 ÷ 0.054 mm
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
Characteristic
Distance between the shoulders
55.67 ÷ 55.85 mm
- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces
shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
STANDARD DIAMETER
Specification
Category 1
Class 2
ENG - 110
Desc./Quantity
28.998 ÷ 29.004
28.004 ÷ 29.010
Liberty 125 - 200 4tempi
Engine
Inspecting the crankshaft alignment
To install the drive shaft on the support and to
measure the misalignment in the 4 points indicated
in figure.
- Check that the driving shaft cone, the tab seat,
the oil seal capacity, the toothed gear and the
threaded tangs are in good working order.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be replaced. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 111
Engine
Inspecting the crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean the all surfaces and oil
ducts.
- On the transmission side crankcase half, take
particular care cleaning the housing and oil ducts
for the following components: the oil pump, the oil
by-pass valve, the main bushings and the cooling
jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKS CAN CAUSE A CONSIDERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD .
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the flywheel side oil seal.
N.B.
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
- Inspect the mating surfaces on the crankcase
halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder
and the mating surfaces between the crankcase
halves.
- Defects in the crankcase coupling gasket or the
surfaces indicated in the figure can cause a drop
in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.
ENG - 112
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and dimensions.
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one containing holes and channels for
lubrication and the other solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposed the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
shown in the figure.
- The oil supply channel section is also affected by
the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THIS POSITION OF THE BUSHINGS ON THE
CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE
HALVES.
Characteristic
Standard driving depth
1.35 ÷ 1.6
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
ENG - 113
Liberty 125 - 200 4tempi
Engine
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
3 - The main bushings are subdivided into 3 thickness categories; see the table below:
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE
THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification
B
C
E
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two
screws to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
- Fit the oil filter joint and tighten it to the prescribed
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, together with the locating dowels.
Locking torques (N*m)
Locking torque 27 ÷ 33
ENG - 114
Desc./Quantity
Blue
Yellow
Green
Liberty 125 - 200 4tempi
Engine
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 11 screws and tighten them to the prescribed torque.
N.B.
WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Lubricate the flywheel oil seal.
- Use the appropriate tool to assemble the oil seal.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the pre-filter on the engine with its corresponding cover to the specific torque.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE
BETTER SEALING PERFORMANCE.
N.B.
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Locking torques (N*m)
Locking torque 24 ÷ 30
Lubrication
ENG - 115
Engine
Conceptual diagrams
ENG - 116
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Oil pressure check
- After removing the cover protections as described in the "Flywheel" chapter, disconnect the electrical connexion of the minimum oil pressure
switch and then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 ÷ 4.2 atm.
- Remove the appropriate tools once the measurement is complete, refit the oil pressure switch
and washer, tightening it to the prescribed torque
and fit the fan cover.
- If the oil pressure is outside the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
N.B.
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD
CONDITION.
Characteristic
Minimum pressure admitted
3.2 atm.
Locking torques (N*m)
Locking torque 12 ÷ 14 (also valid for the control connector).
Crankshaft oil seals
ENG - 117
Engine
Removal
- Remove the transmission cover and the complete drive pulley beforehand
- Install the base of the appropriate tool on the oil
guard using the screws provided.
- Screw the threaded bar onto the base of the tool
and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Prepare the new oil guard, lubricating the sealing
lip. Warning: do not lubricate the surface for keying
onto the engine crankcase.
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ONTO THE
ENGINE CRANKCASE.
ENG - 118
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Preassemble the oil seal with the appropriate
tool, positioning the screws
- Place the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
SHEATH.
- Orientate the oil guard by inserting the bracket
which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
ENG - 119
Engine
Liberty 125 - 200 4tempi
- Use the nut to move the base of the tool until you
can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
Oil pump
Removal
- Remove the chain cover acting on the 3 retaining
screws as shown in the figure and the relevant
copper washer.
- Extract the cover using the appropriate appendages.
N.B.
WITH THE AIM OF AVOIDING DAMAGING THE APPENDAGES PRACTICE A RUN PARALLEL TO CRANKSHAFT.
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
using a screwdriver inserted through one of its two
holes.
ENG - 120
Liberty 125 - 200 4tempi
Engine
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the pulley.
- Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as
shown in the figure.
- Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.
- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the
clip.
- Using a thickness gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted
0.12 mm
ENG - 121
Engine
Measure the distance between the outer rotor and
the pump body; see figure.
Characteristic
Admissible limit clearance:
0.20 mm
Check the axial clearance of the rotors with a trued
bar as reference, as shown in the figure.
Characteristic
Limit values admitted:
0.09 mm
Refitting
- Check there are no signs of wear on the oil pump
shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the assembly.
- Fit the pulley to the pump, the central screw to
the specified torque and the belleville washer.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER
(CURVED) RIM TOUCHES THE PULLEY.
Locking torques (N*m)
Central screw 12 ÷ 14 Nm Cover screws 0.7 ÷ 0.9 Nm
ENG - 122
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
Removing the oil sump
- Remove the oil filler plug, the transmission cover,
the complete drive pulley assembly with belt and
the sprocket wheel, as described in the Transmission chapter.
- Drain the oil from the sump as described above.
- Remove the 7 screws indicated in the figure and
the 2 rear brake transmission fixing brackets.
- Remove the spring, the by-pass piston and the
gasket shown in the second image.
Inspecting the by-pass valve
- Check the unloaded spring length.
- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 123
Engine
Refitting the oil sump
- Refit the by-pass valve plunger in its housing.
- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake transmission support brackets and the screws in the reverse order from which
they were removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as described in the "Transmissions" chapter.
- When testing the lubrication system, refer to
the "Crankcase and Crankshaft" chapter, regarding lubrication of the crankshaft and connecting rod
Locking torques (N*m)
Locking torque 11 ÷ 13
Fuel supply
- Disconnect the fuel supply and the suction taking
pipe from the carburettor.
- Check that there are no fuel leaks between the
two tubes.
- Close the fuel outlet pipe.
- By means of the MITYVAC pump apply 0.1 bar
of suction to the tap.
- Make sure that the suction is kept stable and that
and that there are no fuel leaks.
- Reconnect the 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.
ENG - 124
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
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 MityVac vacuum-operated pump
Characteristic
Minimum flow rate
20 cc
- 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.
Removing the carburettor
- Follow the steps described in Chapter Cylinder
Head and Timing Components.
- Remove the run-off tube and the float bowl
breather tube.
- Remove the carburettor heater.
ENG - 125
Engine
- Remove the guard, the bracket and the autochoke unit.
- Remove the two screw fasteners and the autochoke support, together with the gasket.
- Remove the screw fastener shown in the diagram, the lever and the accelerator pump spring.
- Remove the two screw fasteners shown in the
diagram, the venturi cover and the spring.
- Remove the needle valve together with the diaphragm.
WARNING
DURING THE REMOVAL OF THE COVER TAKE SPECIAL
CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
ENG - 126
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Remove the four screw fasteners shown in the
diagram and the float bowl, together with the gasket.
- Remove the accelerator pump piston together
with the washer, the boot, the O-ring and the
spring, as shown in the diagram.
- Support the carburettor well and, using a mallet
and narrow drift, remove the float pin from the
throttle side.
- Remove the float and the needle.
- Remove the starter jet cap shown in the diagram.
ENG - 127
Engine
-Remove the maximum nozzle.
-Remove diffuser.
- Remove the sprayer tilting the carburettor body.
N.B.
THIS OPERATION IS NECESSARY TO AVOID LOSING
SPRAYER PARTS WHEN CLEANING THE CARBURETTOR
BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO
NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
-Remove the minimum nozzle.
ENG - 128
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Remove the idle flow screw with the O-ring and
the spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS:
FUEL SUPPLY PIPE, PIN SEATING, STARTER NOZZLE, THROTTLE VALVE CONTROL VALVE
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS
ARE CAULKED AFTER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT.
Refitting the carburettor
- Before refitting, wash the carburettor body accurately with a degreasing solvent and compressed
air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
- Clean the main air jet shown in the diagram.
ENG - 129
Engine
Liberty 125 - 200 4tempi
- For the minimum circuit, make sure the following
points are properly cleaned: air gauging, outlet
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe
properly with the jet. This is necessary because
the nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
The acceleration nozzle outlet is extremely small
and is oriented to the throttle valve.
- Check there are 5 ball bearing seals pressed into holes machined in the carburettor body
- Check that the two mating surfaces, between the float bowl and the diaphragm, are unblemished.
- Check the float valve housing channel shows no signs of scoring.
- Check the butterfly valve and control arm.
- Check the valve seat shows no signs of abnormal or excessive wear.
- If any of the above defects are observed, replace the carburettor with a new one.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
ENG - 130
Liberty 125 - 200 4tempi
Engine
- Accurately wash and blow the components of the
maximum circuit, the sprayer, the diffuser and the
nozzle.
- Introduce the sprayer in the carburettor body with
the bigger cylindric part directed to the diffuser.
- Fit the diffuser.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock absorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing
or on the contact plate with the rod and that there
are no fuel infiltrations.
- Replace it in case of anomalies.
- Fit the float together with the pin and rod in its
position and lock it with its screw.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT
PLATE ADEQUATELY
Level check
- Holding the carburettor upside-down, check that
the float is parallel to the plane of the float bowl.
- If found to be out of alignment, adjust by bending
the metal tab that controls the needle, until corrected.
- When making adjustments to the metal tab, ensure it remains parallel to the pin on which the float
hinges.
- Thoroughly clean, blow out and re-fit the starter
jet cap
N.B.
ABSENCE OF THE STARTER JET CAP WILL CAUSE OLD
FUEL WILL BE TAKEN FROM THE BOTTOM OF THE
FLOAT BOWL AND HENCE POOR STARTING.
ENG - 131
Engine
- Remove the float bowl drain screw, thoroughly
clean it and blow out the passage.
- The float bowl vent and the accelerator pump
contain one-way valves and, as such, should be
blown out gently with compressed air from inside
the float chamber.
- Check there are no signs of wear either on the
accelerator pump piston or the corresponding seat
in the float bowl.
- Replace defective components.
- Check the spring on the accelerator pump piston
shows no signs of wear.
- Re-fit the accelerator pump piston in the float
bowl, using a new O-ring and a new boot.
- Re-fit the float, together with the needle, inserting
the pin from the fuel inlet side.
- Check the seal on the screw by introducing a little
petrol into the float bowl.
- Assemble a new boot on the float bowl.
- Re-fit the float bowl to the carburettor body, by
tightening to the specified tightening torque.
- Thoroughly clean the mixture screw, blow out the
passage and re-assemble, using a new O-ring.
- Re-assemly takes the following order: spring,
washer and O-ring.
- Screw the mixture screw into the carburettor
body.
- The final position of the screw must be set according to analysis of the exhaust gas.
- Prepare the carburettor for setting-up, by opening
the mixture screw two full turns from the closed
position.
ENG - 132
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Check the accelerator pump control arm shows
no signs of abnormal or excessive wear.
- Check the clearance of the arm, at the end of its
travel, is 3 ± 0.1 mm
- Check the return spring on the accelerator pump
control arm has not been over-extended or deformed.
- Pre-fit the spring to the control arm as shown in
the diagram.
- Re-fit the control arm to the carburettor body,
whilst holding the butterfly valve open.
- Tighten the control arm screw fastener to the
specified tightening torque.
- Once assembled, check the mechanism is working correctly.
Inspecting the valve and needle
- Undo the bayonet fitting by rotating it 1/8th of a
turn, remove the fitting and remove the vacuum
valve needle and spring.
- Check the needle for signs of wear and that the
stay is set on the second notch from the top.
- Check there are no signs of scoring on the outside of the valve.
- Check the two fuel supply holes are unobstructed.
N.B.
THESE TWO HOLES ARE OF DIFFERENT DIAMETERS
ENG - 133
Engine
- Check the diaphragm has not hardened and is
not broken.
- Replace with a new one if necessary.
- Re-fit the needle to the vacuum valve.
- Ensure the spring is correctly positioned, both on
the needle and in its seat.
- Push and turn the bayonet fitting 1/8th of a turn,
back into position.
- Re-fit the vacuum petrol valve on the carburettor
body, ensuring that the needle is inserted in the
atomiser.
- Gradually screw in the vacuum valve to the point
where the lobe on the diaphragm locates in its
notch; with the valve in such a position, the main
vacuum opening should be in line with the axis of
the bore of the carburettor, offset towards the butterfly valve side.
- Re-fit the spring on the valve.
- Re-fit the vacuum chamber cover, aligning the
reference mark on the cover with the one on the
diaphragm.
- Tighten the screw fasteners to the specified tightening torque.
- Take off the auto-choke seat and blow it out.
- Replace the gasket with a new one and tighten
the two screw fasteners.
Inspecting the automatic choke device
- Inspect the auto-choke piston for signs of scoring
and oxidation.
- Check the auto-choke piston does not stick, but
is free to move back and forth in its housing.
- Check the gasket is not deformed.
- The auto-choke piston should be more or less
fully retracted at room temperature.
- Measure the distance by which the auto-choke
piston projects.
ENG - 134
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- Ensure the piston is retracted at room temperature.
Characteristic
Piston projection starter automatico Walbro
10 mm ~ 24°C
- The auto-choke piston should gradually extend
when power is supplied to its electrical heater terminals.
- Check the resistance across the auto-choke terminals at room temperature.
Electric characteristic
keihin choke device resistor
30 - 40 Ω
- Connect a battery to power the automatic choke for 5 minutes and check that the piston extends fully.
- The actual time to warm up is dependent on ambient temperature.
- If the automatic choke protrudes, sticks or requires times other than those specified, replace it with a
new one.
- Re-fit the auto-choke unit to the carburettor, ensuring the O-ring is correctly located and the
knurled side of the clamping plate is facing downwards, then tighten the two screw fasteners.
- The correct auto-choke position is indicated in the
diagram.
- Place the protective hood over the auto-choke.
- Check the resistance across the carburettor heater terminals at room temperature.
- If the heater resistance varies significantly from
the specified value, replace it with a new one. - Refit the carburettor heater.
- Re-fit the float bowl vent tube and the run-off
tube.
- Re-fit the carburettor, following the steps described in Chapter Cylinder Head and Timing Components.
Electric characteristic
Resistance at room temperature
ENG - 135
Engine
~ 15 Ω
Adjusting the idle
- The engine does not need frequent idle adjustments, however it is very important to make any
adjustments fully respecting some standards.
- Before adjusting the carburettor make sure to respect the lubrication requirements, valve clearance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 minutes at approximately 50 kph.
- Connect the vehicle to the exhaust fumes analyser inserting the probe into a sealed extension pipe
placed at the muffler exit end.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly prepared for probes.
- Start the motor and before adjusting the idle
speed make sure that the oil temperature is between 70 ÷ 80°C.
- Using the rpm indicator or any other instrument
(020332y), adjust the idle screw to obtain 1600
rpm ÷ 1700 rpm
- Adjust the flow screw until the carbon monoxide
(CO) percentage is 3.1 ÷ 4.5%, when the screw is
loosened the CO value rises (rich mix). Tightening
the screw decreases the CO (lean mix).
- If the adjustment of the flow screw causes a rpm
increase readjust the revs again and if necessary,
the flow screw to reach stable values.
- When the oil temperature, the numbers of revs
and the percentage of carbon monoxide are respected the idle carburetion is considered correct.
From the analyser we can draw further information:
ENG - 136
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Engine
- carbon dioxide percentages (CO2), the percentage of carbon dioxide has an inverted course compared to the percentage of(CO), values over
12.5% are considered correct. Non complying values indicate lack of tightness in the exhaust system.
- Unburned hydrocarbons (HC) are measured in
parts per million (PPM). The HC value decreases
while the rpm increases; with the engine at idle it
is normal to detect 200 ÷ 400 PPM, these emission
values are deemed normal for an engine with a
diagram of distribution for motorcycles. Higher values can cause loss of engine blows as the mixture
is too lean (low CO), ignition failure or, incorrect
timing or a clogged or unsealed exhaust valve.
- If it were difficult to ???? adjustment CO check
accurately:
- That the carburettor is clean
- That the automatic starter is efficient
- Tapered pin housing efficiency
- Tank level adjustments
N.B.
THE EXTENSION TUBE IS INDISPENSABLE SO AS NOT
TO SEND POLLUTED EXHAUST FUMES TO THE AMBIENT
OXYGEN. IT IS INDISPENSABLE TO USE AN EXHAUST
FUMES ANALYSER PREVIOUSLY HEATED AND PREPARED TO GUARANTEE THE RESET OF THE READING
OF GASES AND THE CORRECT GAS CAPACITY. FAILURE
TO RESPECT THESE REGULATIONS RESULTS IN INACCURATE READINGS.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED.
CORRECT COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000
Characteristic
Idle adjustment: Pipe sizes
Ø 40 mm
Idle adjustment: length
500 ÷- 600 mm
ENG - 137
INDEX OF TOPICS
SUSPENSIONS
SUSP
Liberty 125 - 200 4tempi
Suspensions
Front suspension
This section is devoted to operations that can be
carried out on the suspension.
Front
Front wheel hub overhaul
Ball bearings to hub
- Fit the spacer
- Fit the ball bearings and bushes and position the
seal rings.
WARNING
PRIOR TO REASSEMBLY, LUBRICATE WITH JOTA 3 F.S.
GREASE IN THE AREAS MARKED WITH THE ASTERISK.
Handlebar
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.
SUSP - 139
Liberty 125 - 200 4tempi
Suspensions
Front fork
Overhaul
O-ring renewal and rod disassembly
- 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).
- 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
Lower and
upper seating
on the chassis
Steering bearing
Steering collar
SUSP - 140
Testo Breve
(< 4000 car.)
Indirizzo
Immagine
Liberty 125 - 200 4tempi
Suspensions
Steering lock ring nut
Steering bearing upper race
- 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
Upper bearing washer and race
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.
Lower and upper races from frame
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
Rear
SUSP - 141
Suspensions
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.
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
Assembly and staking of stand pivot pin to bracket
SUSP - 142
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Suspensions
- 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.
Changing the complete stand
- 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
Expelling stand pivot pin from 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 - 143
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Liberty 125 - 200 4tempi
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
Rear brake calliper
Refitting
Insert the following parts into the calliper half bodies:
- sealing rings (1-2);
- pistons (3);
- fit O-ring seal (4) in one of the pump bodies.
- Couple the inner and outer bodies by means of
the coupling bolts. Fit the pads and bleed air from
the system (see previous paragraphs).
- Position the caliper on the disc and fasten it to
the support, tightening the bolts.
- Secure the tube connection to the caliper with the
required torque.
- Before reassembly, the parts must be perfectly
clean and bear no traces of oil, diesel fuel,
grease, etc.. They must therefore be washed thoroughly in denatured alcohol before proceeding.
Immerse the seals in brake fluid; the use of protective agent PRF1 is tolerated.
CAUTION
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.
Locking torques (N*m)
BRAK SYS - 145
Braking system
Liberty 125 - 200 4tempi
Screw tightening calliper to the support 20 ÷ 25
Calliper to tube connection 8 ÷ 12 Nm
Front brake calliper
Removal
- Detach the oil brake hose from calliper, pouring
the fluid inside a container.
- Remove the mountings indicated in the figure.
- When refitting, tighten the nuts to the prescribed
torque.
- Bleed the system.
Locking torques (N*m)
Calliper tightening screw 20 ÷ 25 Nm Brake fluid
tube calliper 20 ÷ 25
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.
Refitting
Insert the following parts into the calliper half bodies:
- sealing rings (1-2);
- pistons (3);
- fit O-ring seal (4) in one of the pump bodies.
- Couple the inner and outer bodies by means of
the coupling bolts. Fit the pads and bleed air from
the system (see previous paragraphs).
- Position the caliper on the disc and fasten it to
the support, tightening the bolts.
BRAK SYS - 146
Liberty 125 - 200 4tempi
Braking system
- Secure the tube connection to the caliper with the
required torque.
- Before reassembly, the parts must be perfectly
clean and bear no traces of oil, diesel fuel,
grease, etc.. They must therefore be washed thoroughly in denatured alcohol before proceeding.
Immerse the seals in brake fluid; the use of protective agent PRF1 is tolerated.
CAUTION
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.
Locking torques (N*m)
Screw tightening calliper to the support 20 ÷ 25
Calliper to tube connection 8 ÷ 12 Nm
1 DUST GUARDS
2 SEALING RINGS
3 PLUNGERS
4 O-RING GASKET
Front brake disc
Removal
- Remove the front wheel loosening the axle
clamp.
-Remove the six fastenings of the disc.
Refitting
-When refitting, position the disc correctly making sure that it rotates in the right direction.
Locking torques (N*m)
Disc tightening screw 8 - 12
BRAK SYS - 147
Braking system
Liberty 125 - 200 4tempi
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 support for dial gauge
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.
Refitting
- To reassemble perform the above steps in reverse order. Position the leaf spring with the arrow facing
up.
Fill
BRAK SYS - 148
Liberty 125 - 200 4tempi
Braking system
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.
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 MityVac vacuum-operated pump
Recommended products
BRAK SYS - 149
Braking system
Liberty 125 - 200 4tempi
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
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.
BRAK SYS - 150
Liberty 125 - 200 4tempi
Braking system
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.
5. Sealing ring.
6. Piston.
7. Gasket.
8. Spring.
BRAK SYS - 151
INDEX OF TOPICS
CHASSIS
CHAS
Liberty 125 - 200 4tempi
Chassis
Taking apart approached cover motor
Remove the 2 implantations.
Seat
- Unscrew the 2 fixing screws and remove the saddle
Saddle
After checking the homologation specifications, it was concluded that the strap on the saddle is redundant. Please note that the passenger saddle comes without strap since last May. The design number
remains unchanged.
Side fairings
- Remove the countershield
- Unscrew the 4 screws securing it and remove the bumper band
See also
Knee-guard
CHAS - 153
Chassis
Rear rack
• Operating from the rear and using a screwdriver,
remove the plastic cap of the central screw cover.
• Remove the central and the 2 side screws.
Driving mirrors
• With the register screw completely tightened,
screw the mirror stem all the way down on the
handlebars.
• Loosen the mirror and put it in the desired position.
• Loosen the register screw until the stem is tightened.
Locking torques (N*m)
Mirror register screw 24÷26
CHAS - 154
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Chassis
Rear handlebar cover
• Remove the front handlebar fairing
• Unscrew the speedometer transmission connection and remove it
• Disconnect the instrument unit and electrical control connections
• Cut the band holding the front brake hoses to the
instrument unit
• Remove the screw securing the instrument unit
to the handlebar
See also
Front handlebar cover
Instrument panel
• Remove the rear handlebar fairing
• Unscrew the 4 screws securing it and remove the
instrument unit
N.B.
THE BULBS HAVE BAYONET COUPLING ON THE LAMPHOLDER; THE LAMP-HOLDER CAN BE REMOVED BY ROTATING IT 30° ANTI-CLOCKWISE. THE CLOCK RUNS ON
A BATTERY
See also
Rear handlebar cover
CHAS - 155
Chassis
Front handlebar cover
• Remove the 2 screws in the rear handlebar cover
and the screw under the headlamp.
• Pull up and detach the front handlebar cover,
disconnect the headlight assembly connections.
Headlight assy.
• Remove the front handlebar fairing
• Unscrew the 4 screws securing it and remove the
headlight
N.B.
TO REPLACE THE HIGH BEAM/DIPPED BEAM BULB THE
RUBBER COVER MUST BE REMOVED AND THE SUPPORT PLATE ROTATED 30° ANTI-CLOCKWISE. TO REPLACE THE POSITION LIGHT BULB, JUST REMOVE IT
FORM THE RUBBER LAMP-HOLDER.
See also
Front handlebar cover
CHAS - 156
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Chassis
Frame central cover
• Remove the rear luggage rack
• Remove the saddle
• Remove the spark plug access cover, unscrew
the 2 screws joining the helmet compartment
clamp with the footrest.
• Unscrew the 2 side screws placed on the bumper rings.
• Remove the cover by holding it from the rear part and disconnect the turn indicator light connections
See also
Rear rack
Seat
Legshield
• Remove the countershield
• Remove the footrest
• Remove the front steering tube
• Remove the front shield using a blade and working carefully on the right side of it
• Unscrew the screw below and lift off the cover
• Unscrew the front screw securing the shield
CHAS - 157
Chassis
• Unscrew the lower 2 screws, then remove the
shield after having disconnected the turn signal
connections
See also
Knee-guard
Footrest
Knee-guard
• Remove the 4 external screws of the countershield and the 3 located inside the front glove box
• Use the bag clip to pull the countershield back
until releasing it with the front shield
CHAS - 158
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Chassis
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.
See also
Knee-guard
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.
Taillight assy.
• To remove the taillight and position light or the 2
turn signals, just unscrew the screws located on
the related light covers and disconnect the electrical connections.
N.B.
REMOVAL OF THE REAR LIGHT BULBS IS ONLY POSSIBLE BY REMOVING THE LIGHT COVERS ROTATING
THEM 30° ANTI-CLOCKWISE.
CHAS - 159
Chassis
Footrest
• Remove the countershield
• Remove the frame central cover
• Unscrew the screws that secure the passenger
footrest and remove it
• Unscrew the footrest stop screw and remove the
tab
• Remove the 2 external rubber caps of the screws
securing the footrest and unscrew them
• Pull the footrest up being careful of the lower
hooks
See also
Knee-guard
Frame central cover
License plate holder
• Remove the saddle compartment cover
• Unscrew the 2 screws securing it to the frame,
then remove the license plate housing
See also
Frame central cover
CHAS - 160
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Chassis
Air filter
• Unscrew the 7 cover screws and remove the
cover to reach the filter sponge.
• To disassemble the filter housing, unscrew the 2
bottom screws and disconnect the manifold connections, the carburettor and the external air intake.
Rear mudguard
• Remove the 3 screws securing it on the left side
(including the 2 screws securing the air filter box)
• Remove the screw on the side of the cooling casing
• Remove the mudguard by taking it off the muffler
side.
Please take note that, starting from chassis serial number ZAPM3840000005931, a washer drawing
709047 has been added in order to guarantee the rear mudguard correct fixing
CHAS - 161
Chassis
Helmet bay
• Remove the helmet compartment central cover.
• Remove the battery and the fuse box.
• Remove the fuel tank cap and the start-up remote
control switch.
• Unscrew the rear fixing screw and lift the helmet
compartment.
See also
Frame central cover
Frame central cover
spoiler
• Remove the footrest
• Unscrew the two front screws securing it and then
remove the spoiler from the bottom
See also
Footrest
Fuel tank
• Remove the central saddle compartment cover
• Unscrew the front and rear screws on the right
side of the frame
• Disconnect the vent tube and disassemble the
float
CHAS - 162
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Chassis
See also
Frame central cover
Front mudguard
• Leaving the front wheel assembled, disassemble
the steering tube from the vehicle
• Unscrew the 3 screws securing it and remove
them
• Remove the speedometer transmission and
brake hose, then remove the mudguard
N.B.
WHEN REASSEMBLING BE CAREFUL TO POSITION THE
2 METAL GROMMETS TO AVOID ANY RUBBING AGAINST
THE WHEEL.
Top-case
Front
Disassembling the inner shield fairing (glove box ass.y)
- Remove the two screws from inside the glove
box.
CHAS - 163
Chassis
- Remove the two screws at the lower part of the
inner shield fairing
- Remove the two screws located behind the front
grille.
CHAS - 164
Liberty 125 - 200 4tempi
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Liberty 125 - 200 4tempi
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting plastic parts
- 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, low beam, position and parking lights and the respective 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 and temperature indicator
- Instrument panel warning lights
- Horn
- Starter
PRE DE - 166
Liberty 125 - 200 4tempi
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 EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS
AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO
BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
PRE DE - 167
Pre-delivery
Liberty 125 - 200 4tempi
Static test
Static control after the test ride:
- Starting when warm
- Starter operation
- Minimum hold (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
CAUTION
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 - 168
INDEX OF TOPICS
TIME
TIME
Liberty 125 - 200 4tempi
Time
Engine
ENGINE
1
TIME - 170
Code
001001
Action
engine from frame - removal and refitting
Duration
Liberty 125 - 200 4tempi
Time
Crankcase
CRANKCASE
1
2
Code
001133
001153
3
002031
Action
Engine crankcase - Replacement
Half crankcase gasket - Replacement
Rear wheel hub bearings - Replacement
Duration
TIME - 171
Liberty 125 - 200 4tempi
Time
Crankshaft
DRIVING SHAFT
1
2
TIME - 172
Code
001117
001099
Action
Crankshaft - Replacement
Oil seal, flywheel side - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Cylinder assy.
CYLINDER GROUP
1
2
Code
001002
001107
Action
Cylinder-Piston - Replacement
Cylinder / piston - Inspection / cleaning
Duration
TIME - 173
Liberty 125 - 200 4tempi
Time
Cylinder head assy.
HEAD UNIT
1
2
3
TIME - 174
Code
001045
001056
001126
Action
Valves - Replacement
Head gasket - change
Head - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT
1
2
3
Code
001044
001148
001049
Action
Camshaft - Replacement
Rocking lever valve - Replacement
Valves - Adjustments
Duration
TIME - 175
Liberty 125 - 200 4tempi
Time
Cylinder head cover
HEAD COVER
1
2
3
4
5
6
7
TIME - 176
Code
001089
001088
001159
001093
001097
001091
001074
Action
Head cover - Replacement
Head cover gasket - Replacement
Oil vapour recovery tank - Service
Spark plug - Replacement
Cooling hood - Replacement
Head cover sealing ring
Oil vapour recovery pipe - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Chain tensioner
CHAIN TIGHTENER
1
Code
001129
2
001124
Action
Chain tensioner - Service and Replacement
By pass lubrication - Replacement
Duration
TIME - 177
Liberty 125 - 200 4tempi
Time
Oil filter
OIL FILTER
1
2
3
4
TIME - 178
Code
001123
001160
003064
001102
Action
Oil filter - Replacement
Oil pressure sensor - Replacement
Engine oil - Change
Mesh oil filter - Replacement / Cleaning
Duration
Liberty 125 - 200 4tempi
Time
Flywheel cover
FLYWHEEL COVER
1
2
Code
001087
001163
3
001161
4
5
001174
001164
Action
Flywheel cover - Replacement
Secondary air-exhaust manifold Replacement
Secondary air filter - Replacement /
Cleaning
SAS valve - Replacement
Secondary air-crankcase manifold Replacement
Duration
TIME - 179
Liberty 125 - 200 4tempi
Time
Driven pulley
DRIVEN PULLEY - CLUTCH
1
2
3
4
TIME - 180
Code
001155
001022
001012
001110
Action
Clutch bell housing - Replacement
Clutch - Replacement
Driven pulley - Overhaul
Driven pulley - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Oil pump
OIL PUMP
1
2
3
4
5
6
7
Code
001051
001125
001042
001112
001130
001100
001122
Action
Belt/Timing chain - Replacement
Chain guide pads - Replacement
Oil pump - Overhaul
Oil pump - Replacement
Oil sump - Replacement
Oil seal clutch side - Replacement
Oil pump chain - Replacement
Duration
TIME - 181
Liberty 125 - 200 4tempi
Time
Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY
1
2
Code
004125
001156
3
4
003065
001010
TIME - 182
Action
Rear wheel axle - Replacement
Gear reduction unit cover - Replacement
Gearcase oil - Replacement
Gear reduction unit - Inspection
Duration
Liberty 125 - 200 4tempi
Time
Driving pulley
DRIVING PULLEY
1
2
3
Code
001066
001086
001177
4
001011
Action
Driving pulley - Removal and refitting
Driving half-pulley - replace
Variator rollers / slides - Replacement
Driving belt - Replacement
Duration
TIME - 183
Time
Transmission cover
Starter motor
TIME - 184
Liberty 125 - 200 4tempi
Liberty 125 - 200 4tempi
Time
STARTING MOTOR
1
2
Code
001020
001017
Action
Starter motor - Replacement
Starter sprocket wheel - Replacement
Duration
Flywheel magneto
MAGNETO FLYWHEEL
1
2
3
4
Code
001109
001173
001067
001058
Action
Cooling fan - Replacement
Rotor - Replacement
Stator - Removal and Refitting
Flywheel - Replacement
Duration
TIME - 185
Liberty 125 - 200 4tempi
Time
Belt cooling duct
BELT COOLING PIPE
1
2
Code
001131
001132
3
001170
TIME - 186
Action
Transmission air inlet - Replacement
Transmission air inlet pipe - Replacement
Air manifold - replacement
Duration
Liberty 125 - 200 4tempi
Time
Carburettor
CARBURETTOR
1
Code
001082
2
3
001013
004122
4
5
6
001081
001008
001063
Action
Carburettor heating resistor - Replacement
Intake hose - Replacement
Carburettor-filter bellow - Replacement
Automatic choke - Replacement
Carburettor - Inspection
Carburettor - Replacement
Duration
TIME - 187
Liberty 125 - 200 4tempi
Time
Exhaust pipe
MUFFLER
1
2
3
Code
001009
001136
001095
Action
Muffler - Replacement
Exhaust emissions - Adjustment
Muffler guard - Replacement
Duration
Silencer fixing
Please take note that, starting from chassis serial number ZAPM3810000003971, the two M8 x 50
silencer fixing flaged head screws have been replaced by two M8 x 50 internal hexagonal cylindrical
head screws.
TIME - 188
Liberty 125 - 200 4tempi
Time
Air cleaner
AIR CLEANER
1
2
Code
001014
001015
Action
Air filter - Replacement/Cleaning
Air filter box - Replacement
Duration
TIME - 189
Liberty 125 - 200 4tempi
Time
Frame
FRAME
1
2
3
TIME - 190
Code
004001
004004
001053
Action
Chassis - Replacement
Stand - Replacement
Stand bolt - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Legshield spoiler
MUFFLER - GLOVE COMPARTMENT
1
2
3
Code
004159
004149
004064
4
5
6
004079
004053
004015
7
004143
Action
Plates / Stickers - Replacement
Shield central cover - Replacement
Front shield, front section - Removal
and refitting
Rear footrest - Replacement
Spoiler - Replacement
Footrest - Disassembly and reassembly
Footrest support - replace
Duration
TIME - 191
Liberty 125 - 200 4tempi
Time
Rear cover
REAR COVER
1
Code
004174
2
3
004065
004131
4
5
004082
004081
TIME - 192
Action
Glove-box remote opening linkage Replacement
Knee-guard - Removal and refitting
Rear rack mounting bracket - Replacement
Glove-box packing - Replacement
Glove comparment door - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Central cover
CENTRAL COVER
1
Code
004059
2
3
4
004106
004085
004013
Action
Spark plug inspection flap - Replacement
Under-saddle band - Replacement
Fairing (1) - Replacement
Side/rear bumper pipes - Replacement
Duration
TIME - 193
Liberty 125 - 200 4tempi
Time
Underseat compartment
UNDERSEAT COMPARTMENT
1
2
Code
005046
004016
3
001027
TIME - 194
Action
Battery cover - Replacement
Helmet compartment - Removal and
Refitting
Filter bellow - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Plate holder
SUPPORT PLATE
1
Code
004136
2
3
005048
005131
4
005031
5
005032
Action
License plate holder support - Replacement
Licence plate holder - Replacement
number plate light support - Replacement
Licence plate light bulb - Replacement
number plate light glass - Replacement
Duration
TIME - 195
Liberty 125 - 200 4tempi
Time
Mudguard
MUDGUARD
1
2
TIME - 196
Code
004002
004009
Action
Front mudguard - Replacement
Rear mudguard - Replacement
Duration
Liberty 125 - 200 4tempi
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 - Replacement
Duration
TIME - 197
Liberty 125 - 200 4tempi
Time
Rear shock-absorber
REAR SHOCK ABSORBER
1
TIME - 198
Code
003007
Action
Rear shock absorber - Removal and
Refitting
Duration
Liberty 125 - 200 4tempi
Time
Steering column bearings
STEERING COLUMN BEARINGS
1
2
Code
003002
003073
Action
Steering fifth wheels - Replacement
Steering clearance - Adjustment
Duration
TIME - 199
Liberty 125 - 200 4tempi
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
004019
2
004018
3
4
5
6
005078
005076
005014
005038
7
004099
TIME - 200
Action
Handlebar rear section - Replacement
Handlebar front section - Replacement
Odometer glass - Replacement
Clock \ Pile - Replacement
Odometer - Replacement
Instrument panel warning light bulbs
- Replacement
Odometer housing - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Handlebar components
HANDLEBAR COMPONENTS
1
2
3
4
5
6
Code
004066
002037
002071
003001
005017
002024
7
003061
8
002060
9
004162
10
11
002059
002063
Action
Rear-view mirror - Replacement
Brake or clutch lever - Replacement
Left hand grip - Replacement
Handlebar - Removal and refitting
Stop switch - Replacement
Front brake pump - Removal and Refitting
Accelerator transmission - Adjustment
Complete throttle control - Replacement
Mirror support and/or brake pump fitting U-bolt - Replacement
Right hand grip - Replacement
Throttle control transmission - Replacement
Duration
TIME - 201
Liberty 125 - 200 4tempi
Time
Swing-arm
SWINGING ARM
1
Code
001072
2
003080
TIME - 202
Action
Engine / frame swinging arm fitting Replacement
Swinging arm on frame - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Brake hoses
BRAKE HOSES
1
Code
002007
2
3
002039
002021
4
002047
Action
Front brake shoes/pads - Remov.
and Refitt
Front brake line - Replacement
Front brake hose - Remov. and Refitt.
Front brake fluid and system bleeding plug - Repl.
Duration
TIME - 203
Liberty 125 - 200 4tempi
Time
Seat
SEAT
1
2
3
TIME - 204
Code
004003
004008
004062
Action
Saddle - Replacement
Luggage rack - Replacement
Luggage rack cover - Replacement
Duration
Liberty 125 - 200 4tempi
Time
Turn signal lights
TURN SIGNAL LIGHTS
1
2
3
Code
005002
005012
005067
4
5
6
7
005008
005005
005066
005028
8
005022
9
005068
Action
Front headlamp - change
Front turn indicator - Replacement
Front turn indicator bulb - Replacement
Front headlamp bulbs - Replacement
Taillight - Replacement
Rear light bulbs - Replacement
Rear light assembly glass - Replacement
Rear turning indicators - Replacement
Rear turning indicator bulb - Replacement
Duration
TIME - 205
Liberty 125 - 200 4tempi
Time
Front wheel
FRONT WHEEL
1
2
3
4
5
Code
003038
002011
003040
003047
003037
6
7
004123
002041
Action
Front wheel axle - Replacement
Odometer drive - Replacement
Front wheel bearings - Replacement
Front tyre - Replacement
Front wheel rim - Removal and Refitting
Front wheel - Replacement
Brake disc - Replacement
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 - 206
Duration
Liberty 125 - 200 4tempi
Time
Rear wheel
REAR WHEEL
1
2
3
4
Code
002002
004126
001016
001071
Action
Rear brake pads/shoes - Repl.
Rear wheel tyre - Replacement
Rear wheel - Replacement
Rear wheel rim - Removal and Refit
Duration
TIME - 207
Liberty 125 - 200 4tempi
Time
Electric devices
ELECTRICAL DEVICES
1
2
Code
001023
005035
3
005001
4
5
6
7
8
9
001094
001069
005052
005025
005009
005011
10
11
005007
005114
TIME - 208
Action
Control unit - Replacement
Headlight remote control - Replacement
Electric system - Removal and reassembly
Spark plug cap - Replacement
HV coil - replace
Fuse - Replacement
Battery fuse box - Replacement
Voltage regulator - Replacement
Start-up remote control switch change
Battery - Replacement
Electrical system - Service
Duration
Liberty 125 - 200 4tempi
Time
Electronic controls
ELECTRIC CONTROLS
1
2
Code
005039
005006
3
4
5
6
7
8
005040
005003
005041
005016
004096
005072
Action
Lights switch - Replacement
Light or turning indicator switch - Replacement
Horn button - Replacement
Horn - Replacement
Starter button - Replacement
Key switch - Replacement
Lock series - Replacement
Immobilizer aerial - Replacement
Duration
TIME - 209
Liberty 125 - 200 4tempi
Time
Transmissions
TRANSMISSIONS
1
Code
002051
2
3
002049
002053
TIME - 210
Action
Odometer transmission assembly Replacement
Odometer cable - Replacement
Rear brake transmission complete replacement
Duration
Liberty 125 - 200 4tempi
Time
Front suspension
FRONT SUSPENSION
1
2
3
4
5
6
Code
003010
003048
003076
003079
003051
003069
Action
Front suspension - Service
Fork oil seal - Replacement
Fork leg - Replacement
Fork stem - Replacement
Complete fork - replace
Front fork oil - Replacement
Duration
TIME - 211
A
Air filter: 161
B
Battery: 38, 45, 55, 58
Brake: 145–148, 150, 203
C
Carburettor: 11, 125, 129, 187
F
Fuel: 37, 124, 162, 197
H
Headlight: 156
Horn:
I
Identification: 8
Instrument panel: 155
M
Maintenance: 7, 29
Mirrors: 154
O
Oil filter: 178
S
Shock absorbers: 142
Spark plug: 53
Start-up:
T
Tank: 162, 197
Transmission: 10, 37, 65, 80, 90, 184
Turn indicators:
Tyres: 10
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