Derbi Rambla 125 (en)

NACIONAL MOTOR, S.A.U. DERBI Derbi -

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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

Safety rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.CAUTIONUSE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START-ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THEENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARECOLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVELGROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEMPARTS.DO NOT HOLD ANY MECHANICAL OR OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOT-ER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL ANDEVEN TOXIC.CARBON MONOXIDE

If you need to keep the engine running in order to carry out any procedure, please ensure that you do

so in an open or very well ventilated area.

Never let the engine run in an enclosed area.

If you do work in an enclosed area, make sure to use a smoke-extraction system.CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSELOSS OF CONSCIOUSNESS AND EVEN DEATH.FUELCAUTION

FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EX-PLOSIVE UNDER SPECIFIC CONDITIONS.IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PRO-CEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF.DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACTWITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITEOR EXPLODE.CAUTION

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.CAUTION

KEEP OUT OF THE REACH OF CHILDREN.HIGH-TEMPERATURE COMPONENTS

Characteristics

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The engine and the components of the exhaust system can get very hot and remain hot for some time

even after the engine has been switched off.

Before handling these components, make sure that you are wearing insulating gloves or wait until the

engine and the exhaust system have cooled down.

TRANSMISSION OIL AND USED FORK OILCAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FORLONG PERIODS.WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLINGCOMPANY OR THE SUPPLIER.IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.CAUTION

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.CAUTION

KEEP OUT OF THE REACH OF CHILDREN.

BRAKE FLUIDCAUTION

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICINGTHE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM.THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITHABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.CAUTION

KEEP OUT OF THE REACH OF CHILDREN.

HYDROGEN GAS AND BATTERY ELECTROLYTECAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-TECTIVE APPAREL.IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANTCOOL WATER.IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTSOF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,

Characteristics

CHAR - 7

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL-IST AS SOON AS POSSIBLE.IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL-LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE-LY.THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-RETTES OR ANY OTHER HEAT SOURCE.ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.CAUTION

KEEP OUT OF THE REACH OF CHILDREN.CAUTION

THE BATTERY LIQUID IS CORROSIVE.DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-VATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.CAUTION

UNLESS OTHERWISE INDICATED, REFIT THE UNIT FOLLOWING THE REMOVAL STEPS BUTIN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THEOTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY RE-MOVAL OF COMPONENTS. DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES.NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER.DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTSAND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD.DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUTELECTRICAL WELDING WORK.

BEFORE REMOVING COMPONENTS

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

Use the special tools designed for this scooter, as required.

REMOVAL OF COMPONENTS

Do not loosen and/or tighten screws and nuts using pliers or other tools than the specially

designed wrench.

Mark positions on all connection joints (pipes, cables etc.) before separating them, and

identify them with distinctive symbols.

Each component needs to be clearly marked in order to be identified during reassembly.

Clean and wash the dismantled components carefully using a low-flammability detergent.

Characteristics

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Keep coupled parts together since they have "adjusted" to each other due to normal wear

and tear.

Some components must be used together or replaced altogether.

Keep away from heat sources.

REASSEMBLING COMPONENTSCAUTION

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITHA NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHEDMORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITSSEAT.DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.NOTE

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-ERWISE THEY NEED REPLACING.

Use only ORIGINAL Derbi SPARE PARTS.

Comply with lubricant and consumables usage guidelines.

Lubricate parts (whenever possible) before refitting them.

When tightening nuts and screws, start from the ones with the largest section or from the

internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-

plying the tightening torque.

Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and

screws with new ones if their tread is damaged.

When fitting bearings, make sure to lubricate them well.

Check that each component is fitted correctly.

After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-

hicle on private grounds or in an area with low traffic density.

Clean all coupling surfaces, oil guard rims and washers before refitting them. Apply a light

layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the

bearings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below as non-compliance with the procedure

so described causes irreparable damage to both the connector and the cable harness: Press the rele-

vant safety hooks, if any.CAUTION

TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.

Grip the two connectors and disconnect them by pulling them in opposite directions.

Characteristics

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In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a

pressurised air jet.

Make sure that the cables are correctly linked to the connector's internal terminal ends.NOTE

THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAYROUND.

Then fit the two connectors making sure that they couple correctly (if the relevant hooks are

provided, you will hear them "click" into place).

TIGHTENING TORQUECAUTION

DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS,BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE INENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS.IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAYBECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COM-PROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISKOF SERIOUS INJURY OR DEATH.

BRAKE FLUIDCAUTION

DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQ-UIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM.DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THATHAVE BEEN OPEN FOR A PROLONGED TIME.SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUETO FAULTS IN THE HYDRAULIC CIRCUIT.MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOTSMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND IN-SPECTION OPERATIONS.CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN.ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY INTO THE CIRCUIT.IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT.

DISC BRAKECAUTION

ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS.SOILED PADS MUST BE REMOVED AND REPLACED. A SOILED DISC OR A DISC WITH TRACESOF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT.IF THE SCOOTER IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS, ORIF IT IS USED FOR SPORTS APPLICATION, HALVE THE SERVICE INTERVALS.

COOLANT

The cooling of the engine is by forced liquid circulation. The coolant liquid is made up of 50% de-ionised

water and antifreeze solution in a base of ethylene glycol and corrosion inhibitors. The product recom-

mended in the 'Recommended products table' is already mixed and ready to use.

Characteristics

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For the best functioning of the engine the temperature of the coolant fluid should register in the central

zone of the appropriate gauge. If the needle enters the red zone, stop the engine, allow it to cool, and

check the level of the fluid; if it is normal, contact an Official Derbi Dealer.CAUTION

DO NOT USE YOUR VEHICLE IF THE COOLANT LEVEL IS BELOW THE MINIMUM LEVELMARKED "MIN".CAUTION

COOLANT IS TOXIC IF INGESTED; CONTACT WITH YOUR EYES OR SKIN MAY CAUSE IRRITA-TION. IF THE FLUID GETS IN CONTACT WITH THE EYES OR SKIN, RINSE REPEATEDLY WITHPLENTY OF WATER AND SEEK MEDICAL ADVICE. IF SWALLOWED, INDUCE VOMITING, RINSEMOUTH AND THROAT WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.CAUTION

DO NOT REMOVE THE EXPANSION TANK PLUG WHEN THE ENGINE IS HOT, SINCE COOLANTIS UNDER PRESSURE AND VERY HOT. CONTACT WITH SKIN OR CLOTHES MAY CAUSE SE-VERE BURNS AND/OR INJURIES.

TYRESCAUTION

CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THATARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS.THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT ISSLIPPERY. DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES (MILES).NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES.IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUELTHAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER.A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOTSIMPLY CLEANED.DO NOT FIT TYRES WITH INNER TUBES ON RIMS FOR TUBELESS TYRES AND VICE VERSA.

Vehicle identification

Chassis number

The chassis number is stamped on the chassis

central bar. Remove the indicated cap placed in-

side the front glove-box in order to read this num-

ber.

Characteristics

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Engine number

The engine number is stamped near the rear

shock absorber lower support.CAUTIONALTERING IDENTIFICATION NUMBERS CAN BE SERI-OUSLY PUNISHED BY LAW, PARTICULARLY MODIFYINGTHE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATETHE WARRANTY.

Dimensions and mass

SIZESSpecification Desc./QuantityMax. length 1965 mm

Max. length (to brake levers (to mirrors)) 720 mm (890 mm)Max. height (to the rear-view mirrors) 1.143 mm

Saddle height 790 mmWheelbase 1360 mm

Minimum ground clearance 130 mmKerb weight 148 kg

Engine

ENGINE TECHNICAL DATA

Specification Desc./QuantityEngine model M281M (125)

M282M (200)Engine type Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication

system, overhead camshaft.Valve quantity 4

Cylinder quantity 1Overall engine capacity 124 cm³ (125)

198 cm³ (200)Bore/stroke 57 mm / 48.6 mm (125)

72 mm / 48.6 mm (200)Compression ratio 12.0 ± 0.5 : 1 (125)

11.5 ± 0.5 : 1 (200)MAX power 11 kW at 10,000 rpm (125)

14 kW at 8,500 rpm (200)MAX. torque 11.7 Nm at 7,500 rpm (125)

19 Nm at 6,500 rpm (200)Start-up Electric

Engine revs at idle speed 1600 ± 100 rpmClutch Automatic centrifugal dry clutch

Lubrication system Wet sump forced lubrication system.Cooling forced-circulation air cooling driven by a centrifugal pump

Valve clearance Inlet: 0.10Outlet: 0.15

Carburettor model (125): CVK7 30 KeihinCarburettor model (200): CVK7 30 Keihin

WVF7 ø29 WALBROSupply Vacuum pumpFuel Use premium unleaded petrol only, with minimum octane rating

of 95 (NORM) and 85 (NOMM).IGNITION Capacitive discharge ignition, variable advance

Ignition advance (125) Variable ignition advance by microprocessor:

Characteristics

CHAR - 12

Specification Desc./Quantity10° ± 1° to 2,000 rpm

34° ± 1° from 4,500 to 10,000 rpmIgnition advance (200) Variable (before TDC) from:

10° ± 1° to 2,000 rpm32° ± 1° to 6,500 rpm

Spark plug NGK CR7EBSpark plug electrode gap 0.7 - 0.8 mm

Transmission

TRANSMISSIONSpecification Desc./Quantity

Gear continuous and automatic variatorPrimary drive V-belt

Secondary With gearsEngine/wheel total ratio 1/6.36 (125)

1/6.54 (200)Minimum ratio for continuos transmission 36.5 (125)

22.36 (200)Maximum ratio for continuos transmission 10.95 (125)

7.88 (200)

Capacities

CAPACITYSpecification Desc./Quantity

Fuel (reserve included) 9 lFuel reserve 1.5 l

Engine oil - engine oil change and engine oil filter replacement 1100 cm³Transmission oil 250 cm³

Fork oil 135±1 cm³ per stem

Depth of fork oil level from the rim / without spring / fork included 99 ± 1.5 mmCoolant 1.5 l (50% water + 50% ethylene glycol antifreeze fluid)Seats 2

Vehicle max. load (rider + passenger + luggage) 210 kg

Electrical system

BULBS/WARNING LIGHTSSpecification Desc./Quantity

1 High-/low-beam bulb 12 V - 55 W - H72 Tail light bulb 12V - 5W3 Front turn indicator bulbs 12 V - 10 W (Amber)4 Rear turn indicator bulbs 12 V - 10 W (White)5 Rear tail light /stop light bulb 12 V - 5/21 W (Red)6 License plate light bulb 12V - 5W7 Instrument panel lighting bulb LED8 Turn indicator warning light LED9 High-beam warning light LED10 Low fuel warning light LED11 Engine oil pressure warning light LED12 High coolant temperature gauge warning light LED

ELECTRICAL SYSTEMSpecification Desc./Quantity

Battery 12V - 10 Ah

Characteristics

CHAR - 13

Specification Desc./Quantity(Permanent magnet) Generator 12V - 180W

Frame and suspensions

CHASSIS AND SUSPENSIONSSpecification Desc./Quantity

Size "A" 423.5 mmSize "B" 479 mm

Trail 86.2 mmChassis type High-strength steel tubular chassis, single spar at the front, su-

perimposed double cradle at the rear.Steering inclination angle 26.5°

Front suspension Hydraulic action telescopic forkFront suspension travel 100 mm

Rear suspension hydraulic action double-acting shock absorber, adjustable pre-loading

Rear suspension travel 80 mm

Brakes

BRAKESSpecification Desc./QuantityFront brake Ø 260-mm disc brake with hydraulic transmissionRear brake Ø 220-mm disc brake with hydraulic transmission

Wheels and tyres

WHEELS AND TYRESSpecification Desc./Quantity

Wheel rims Made of light alloyFront wheel rim 2.75 x 15"Rear wheel rim 3.00 x 15"

Tyres Without inner tube (Tubeless)Front tyre 120/70 - 15'' 56PRear tyre 130/80 - 15'' 63P

Rear tyre standard inflation pressure 200 kPa (2.0 bar)Front tyre standard inflation pressure 200 kPa (2.0 bar)

Front tyre standard inflation pressure with passenger 200 kPa (2.0 bar)Rear tyre standard inflation pressure with passenger 230 kPa (2.3 bar)

Characteristics

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Carburettor

KEY:

1. Minimum jet

2. Maximum jet

3. Idle air set screw

4. Tapered pin

5. Throttle valve return spring

6. Float chamber assy

7. Starter cover

8. Cover

9. Screw

10. Screw

11. Fuel closing float needle

12. Diaphragm

13. Float kit

14. Complete automatic starter

15. Spring

16. Cap

17. Washer

18. Seeger ring

19. Spring

Characteristics

CHAR - 15

20. Washer

21. Acceleration pump kit

125cc Version

Kehin

CARBURETTOR 125 CCSpecification Desc./Quantity

Model CVK7 30 KeihinDiffuser Ø 29 mm

Engine-side coupling Ø 40 mmFloat

Petrol inlet valve needle seat 1.2Start-up air inlet hole 150

Start-up jet 42Minimum jet 35

Idle air screw open in turns 2Minimum air hole 130Maximum air hole 70

Maximum jet 105Throttle valve Standard

Sprayer Ø 2.8 mmTapered pin NDVA

Notch

200cc Version

Kehin

CARBURETTOR 200 CCSpecification Desc./Quantity

Model CVK7 30 KeihinDiffuser Ø 29 mm

Engine-side coupling Ø 40 mmFloat

Petrol inlet valve needle seat 1.2Start-up air inlet hole 150

Start-up jet 42Minimum jet 38

Idle air screw open in turns 2Minimum air hole 115Maximum air hole 70

Maximum jet 100Throttle valve Standard

Sprayer Ø 2.8 mmTapered pin NDVA

Notch

Tightening Torques

HANDLEBARName Torque in Nm

Handlebar to fork retainer 48±20%

Characteristics

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Name Torque in NmSafety screw 20±20%

Steering set nut 15±20%Steering series fixing lock nut 110±20%

Instrument panel support to handlebar retainer 6±20%Mirror supports to handlebar retainer 52±20%

Mirrors retainer 25±20%

CHASSISName Torque in Nm

License plate holder curved support to chassis retainer 25±20%Passenger grab handle to chassis retainer 25±20%

Horn to chassis retainer 10±20%Regulator to chassis retainer 10±20%

Switch to chassis retainer 10±20%Fuel tank to chassis retainer 10±20%

Helmet compartment to chassis retainer 5±20%Air deflector to chassis retainer 5±20%

Coil to chassis retainer 5±20%

ELECTRICAL SYSTEMName Torque in Nm

Starter motor cable retainer 5±20%Battery to relay retainer 4±20%

Starter motor on relay retainer 4±20%Battery cable harness ground lead retainer 10±20%

SADDLEName Torque in Nm

Hinge on saddle retainer 7±20%

LOCKSName Torque in Nm

Glove-box lock on cover retainer 4±20%Saddle lock on right and left half-tail sections retainer 3±20%

Saddle lock on helmet compartment retainer 5±20%

INSTRUMENT PANELName Torque in Nm

Instrument panel to rear panel retainer 0.8±20%Instrument panel to instrument panel support retainer 4.5±20%

Rear panel to handlebar retainer 1±20%Front panel to lower clamp retainer 1±20%Front panel to rear panel retainer 3±20%

Lower clamp to rear panel retainer 1±20%Left and right tool holder retainer 5±20%

REAR BODYWORKName Torque in Nm

Retroreflector to license plate holder retainer 1.5±20%License plate to license plate holder retainer 1±20%

Rear taillight to right and left half-tail sections retainer 1±20%Front retainer for right and left half-tail sections on helmet com-

partment4±20%

Rear retainer for right and left half-tail sections on helmet com-partment

1±20%

Rear light cover on license plate holder retainer 1±20%Rear light cover on helmet compartment retainer 6

Rear light cover on tail sections retainer 1±20%License plate holder on right and left half-tail sections retainer 3±20%

License plate holder on rear mudguard chassis retainer 5±20%Luggage carrier cover on luggage carrier retainer 1±20%

Characteristics

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Name Torque in NmRetainer between passenger grab handle cover and passenger

grab handle1±20%

Right and left half-tail sections on helmet compartment retainer 1±20%Fuel probe lid on helmet compartment retainer 1±20%

Retainer for lower lock of right and left half-tail sections on rightand left half-tail sections

3±20%

CENTRAL BODYWORKName Torque in Nm

Central inspection cover on helmet compartment retainer 1±20%Central inspection cover on right and left fairings retainer 3±20

Left side inspection cover retainer 3±20%Right side inspection cover retainer 3±20%

Battery cover retainer 3±20%Footrest retainer 3±20%

Right and left lower shield retainer 3±20%Glove-box lid on internal legshield retainer 1±20%

Internal legshield to external legshield retainer 1±20%Glove-box net on internal legshield retainer 1±20%

Glove-box lid reinforcing retainer 1±20%Bag hook retainer 1±20%

Air intake on internal legshield retainer 1±20%

FRONT AND REAR BRAKEName Torque in Nm

Calliper on fork retainer 25±20%Calliper on muffler plate retainer 25±20%

Pipe cable guide on link rod retainer 10±20%Pipe cable guide on air deflector retainer 5±20%Right and left pump on handlebar retainer 10±20%

Rear calliper support to muffler plate retainer 25±20%Rear calliper support on muffler plate retainer 25±20%

Front pipe cable guide on fork retainer 10±20%

FRONT BODYWORKName Torque in Nm

Right and left air intake on shield retainer 1±20%Right and left turn indicators on external legshield retainer 1±20%

Front headlamp on external legshield retainer 1±20%External legshield on cover retainer 1±20%External legshield on shield retainer 1±20%

Front mudguard clamp on fork retainer 1±20%External legshield on under-footrest retainer 3±20%

Front mudguard on clamps retainer 5±20%Case on internal legshield retainer 2±20%

FILTER CASINGName Torque in Nm

Sleeve on carburettor retainer 2±20%Sleeve on filter housing retainer 2±20%Filter housing on engine retainer 8±20%

COOLING UNITName Torque in Nm

Thermal switch retainer 20±20%Head pipe on radiator retainer 2±20%Pump pipe on radiator retainer 2±20%Radiator on bulkhead retainer 7±20%Electric fan on radiator retainer 1±20%

Expansion tank on air deflector retainer 4±20%

Characteristics

CHAR - 18

FRONT WHEELName Torque in Nm

Pin retainer 50±20%Safety screw retainer 10±20%

LINK RODName Torque in Nm

Connecting rod to chassis retainer 60±20%Connecting rod to engine retainer 40±20%

Chassis connecting rod on engine connecting rod retainer 60±20%Silent-block on chassis retainer 50±20%

EXHAUSTName Torque in Nm

Manifold to engine retainer 15±20%Muffler to manifold retainer 16±20%

Muffler on plate retainer 25±20%Protection on muffler retainer 7±20%

REAR WHEELName Torque in Nm

Rear wheel retainer 110±20%Speed sensor screw retainer 10±20%

Speed sensor on muffler plate retainer 10±20%

STANDName Torque in Nm

Stand to engine retainer 27±20%

ENGINEName Torque in Nm

Muffler plate on engine 25±20%Fuel breather pipe cable guide on crankcase 10±20%

Anti-vibration roller 12 ÷ 16Driven pulley shaft nut 54 ÷ 60

Clutch assembly nut on driven pulley 55 ÷ 60Driving pulley nut 75 ÷ 83

Flywheel nut 54 ÷ 60Oil filter fitting on crankcase 27 ÷ 33Minimum oil pressure sensor 12 ÷ 14

engine oil drainage plug/mesh filter 24 ÷ 30oil pump driving crown gear screw 10 ÷ 14

Timing chain tensioner support screw 11 ÷ 13Engine crankcase coupling screws 11 ÷ 13

Rear hub cover screws 24 ÷ 27Oil pump cover screws 0.7 ÷ 0.9

Transmission cover screws 11 ÷ 13Oil sump screws 10 ÷ 14

Screws fixing oil pump to crankcase 5 ÷ 6Stator unit screws (°) 3 ÷ 4Starter motor screws 11 ÷ 13

Screws for engine crankcase internal bulkhead (transmission-side half shaft)

4 ÷ 6

REAR SUSPENSIONName Torque in Nm

Right and left shock absorber to chassis retainer 25±20%Shock absorber on engine bracket retainer 40±20%Shock absorber on muffler plate retainer 40±20%

Shock absorber bracket on engine retainer 25±20%

Characteristics

CHAR - 19

FUEL SUPPLY SYSTEMName Torque in Nm

Probe to tank retainer 1.5±20%Fuel coupling clamp retainer 1±20%

Tank to helmet compartment retainer 2±20%Petrol pump on helmet compartment retainer 2±20%

Overhaul data

Assembly clearances

Cylinder - piston assy.125 cm³ Version

COUPLING CATEGORIESName Initials Cylinder Piston Play on fitting

Cylinder A 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059Cylinder B 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059Piston C 57.011 ÷ 57.018 56.959 ÷ 56.966 0.045 - 0.059Piston D 57.018 ÷ 57.025 56.966 ÷ 56.973 0.045 - 0.059

Cylinder 1st Oversize A1 57.197 ÷ 57.204 57.145 ÷ 57.152 0.045 - 0.059Cylinder 1st Oversize B 1 57.204 ÷ 57.211 57.152 ÷ 57.159 0.045 - 0.059Piston 1st Oversize C 1 57.211 ÷ 57.218 57.159 ÷ 57.166 0.045 - 0.059Piston 1st Oversize D 1 57.218 ÷ 57.225 57.166 ÷ 57.173 0.045 - 0.059

Cylinder 2nd Oversize A2 57.397 ÷ 57.404 57.345 ÷ 57.352 0.045 - 0.059Cylinder 2nd Oversize B 2 57.404 ÷ 57.411 57.352 ÷ 57.359 0.045 - 0.059Piston 2nd Oversize C 2 57.411 ÷ 57.418 57.359 ÷ 57.366 0.045 - 0.059Piston 2nd Oversize D 2 57.418 ÷ 57.425 57.366 ÷ 57.373 0.045 - 0.059

Cylinder 3rd Oversize A3 57.597 ÷ 57.604 57.545 ÷ 57.552 0.045 - 0.059

Characteristics

CHAR - 20

Name Initials Cylinder Piston Play on fittingCylinder 3rd Oversize B 3 57.604 ÷ 57.611 57.552 ÷ 57.559 0.045 - 0.059Piston 3rd Oversize C 3 57.611 ÷ 57.618 57.559 ÷ 57.566 0.045 - 0.059Piston 3rd Oversize D 3 57.618 ÷ 57.625 57.566 ÷ 57.573 0.045 - 0.059

200 cm³ Version

COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER)Name Initials Cylinder Piston Play on fitting

Cylinder/Piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044Cylinder/Piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044Cylinder/Piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044Cylinder/Piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044

COUPLING CATEGORIES (WITH CAST-IRON CYLINDER)Name Initials Cylinder Piston Play on fitting

Cylinder/Piston M 72 ÷ 72.007 71.953 ÷ 71.960 0.040 - 0.054Cylinder/Piston N 72.007 ÷ 72.014 71.960 ÷ 71.967 0.040 - 0.054Cylinder/Piston O 72.014 ÷ 72.021 71.967 ÷ 71.974 0.040 - 0.054Cylinder/Piston P 72.021 ÷ 72.026 71.974 ÷ 71.981 0.040 - 0.054

Piston rings125 cm³ Version

Characteristics

CHAR - 21

ENGINE SEALING RINGSName Description Dimensions Initials Quantity

Compression ring 57 x 1 A 0.15 ÷ 0.30Oil scraper ring 57 x 1 A 0.10 ÷ 0.30Oil scraper ring 57 x 2.5 A 0.15 ÷ 0.35

ENGINE SEALING RINGS (1ST OVERSIZE)Name Description Dimensions Initials Quantity

Compression ring 1stOversize

57.2 x 1 A 0.15 ÷ 0.30

Oil scraper ring 1stOversize

57.2 x 1 A 0.10 ÷ 0.30

Oil scraper ring 1stOversize

57.2 x 2.5 A 0.15 ÷ 0.35

ENGINE SEALING RINGS (2 ND OVERSIZE)Name Description Dimensions Initials Quantity

Compression ring 2ndOversize

57.4 x 1 A 0.15 ÷ 0.30

Oil scraper ring 2ndOversize

57.4 x 1 A 0.10 ÷ 0.30

Oil scraper ring 2ndOversize

57.4 x 2.5 A 0.15 ÷ 0.35

ENGINE SEALING RINGS (3 RD OVERSIZE)Name Description Dimensions Initials Quantity

Compression ring 3rdOversize

57.6 x 1 A 0.15 ÷ 0.30

Oil scraper ring 3rdOversize

57.6 x 1 A

Oil scraper ring 3rdOversize

57.6 x 2.5 A 0.15 ÷ 0.35

200 cm³ Version

Characteristics

CHAR - 22

ENGINE SEALING RINGSName Description Dimensions Initials Quantity

Compression ring 72x1.5 A 0.15 ÷ 0.30Oil scraper ring 72 x 1 A 0.10 ÷ 0.40Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40

Crankcase - crankshaft - connecting rod

CRANKSHAFT HALF-BEARINGSName Description Dimensions Initials Quantity

Crankshaft half-bear-ings

B Type - blue 1.973 ÷ 1.976

Crankshaft half-bear-ings

C Type - yellow 1.976 ÷ 1.979

Crankshaft half-bearing E Type - green 1.979 ÷ 1.982

CRANKCASE - CRANKSHAFT COUPLINGSName Description Dimensions Initials Quantity

Crankshaft type 1-Crankcase type 1

E - E

Crankshaft type 1 -Crankcase type 2

C - C


C - C


B - B

CRANKSHAFT - CRANKCASEName Description Dimensions Initials Quantity

Crankshaft Class 1 28.998 ÷ 29.004Crankshaft Class 2 29.004 ÷ 29.010Crankcase Class 1 32.959 ÷ 32.965Crankcase Class 2 32.953 ÷ 32.959

Characteristics

CHAR - 23

Fitting clearances

Crankshaft/crankcase axial clearance (H):

0.15 ÷ 0.40 mm (when cold)

Characteristics

CHAR - 24

CRANKSHAFT / CRANKCASE AXIAL CLEARANCEName Description Dimensions Initials Quantity

Half shaft, transmissionside

16.6 +0-0.05 A D = 0.20 ÷ 0.50

Half shaft, flywheel side 16.6 +0-0.05 B D = 0.20 ÷ 0.50Connecting rod 18 -0.10 -0.15 C D = 0.20 ÷ 0.50

Spacer tool 51.4 +0.05 E D = 0.20 ÷ 0.50

Slot packing system125 cm³ Version

CharacteristicCompression ratio

12 ± 0.5 : 1

Distance « A» to be measured is a value of piston protrusion, it indicates how deep the piston crown

protrudes out of the plane formed by the cylinder crown. The further the piston protrudes out of the

cylinder, the thicker the base gasket to be used should be (to compensate the compression ratio) and

vice versa.NOTE

DISTANCE «A», MEASURED WITH THE PISTON AT THE TOP DEAD CENTER, MUST BE TAKENWITH NO GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESET-TING THE DIAL GAUGE, WITH ITS SUPPORT ON A GROUND SURFACE.

Characteristics

CHAR - 25

METAL HEAD GASKET (0.3)Name Measure A Thickness

Shimming - Cylinder 67.8 - Head gasket0.3 - Base gasket 0.4

1.40 ÷ 1.65 0.4 ± 0.05


1.65 ÷ 1.90 0.6 ± 0.05

200 cm³ Version

CharacteristicCompression ratio

11.5 ± 0.5: 1

Distance « A» to be measured is a value of piston protrusion, it indicates how deep the piston crown

protrudes out of the plane formed by the cylinder crown. The further the piston protrudes out of the

cylinder, the thicker the base gasket to be used should be (to compensate the compression ratio) and

vice versa.NOTE

DISTANCE «A», MEASURED WITH THE PISTON AT THE TOP DEAD CENTER, MUST BE TAKENWITH NO GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESET-TING THE DIAL GAUGE, WITH ITS SUPPORT ON A GROUND SURFACE.

METAL HEAD GASKET (0.3)Name Measure A Thickness


2.50 ÷ 2.40 0.4 ± 0.05


2.40 ÷ 2.20 0.6 ± 0.05

Characteristics

CHAR - 26

Name Measure A ThicknessShimming - Cylinder 67.8 - Head gasket

0.3 - Base gasket 0.82.20 ÷ 2.10 0.8 ± 0.05

Products

RECOMMENDED PRODUCTS TABLEProduct Description Specifications

AGIP RACING 4T, SAE 10W-40 Engine oil 10W-40AGIP GEAR SYNTH SAE 75W-90 Gearbox oil API GL4, GL5

AGIP FORK 7.5W Fork oilAGIP FILTER OIL Oil for air filter sponge -AGIP BRAKE 4 Brake fluid FMVSS DOT4+

SPECIAL AGIP PERMANENT fluid Coolant Biodegradable coolant, ready for use,with "long life" technology and character-

istics (pink). Freezing protection up to-40°. According to CUNA 956-16 stand-

ard.AGIP GREASE SM2 Lithium grease with molybdenum for

bearings and other points needing lubri-cation

NLGI 2

NEUTRAL GREASE OR PETROLEUMJELLY

Battery poles Neutral grease or petroleum jelly.

Characteristics

CHAR - 27

INDEX OF TOPICS

TOOLING TOOL

SPECIFIC TOOLSStores code Description

020622Y Transmission-side oil seal punch

020565Y Flywheel lock calliper spanner

001467Y013 Calliper to extract 15-mm diameter bear-ings

001467Y035 Bell for OD 47-mm bearings

020150Y Air heater support

020151Y Air heater

Tooling

TOOL - 29

Stores code Description020193Y Gauge for oil pressure check

020262Y Crankcase splitting strip

020263Y Sheath for fitting the driven pulley

020287Y Ring to assemble piston on cylinder

020306Y Punch for fitting the valve sealing rings

020329Y Vacuum pump Mity-Vac

Tooling

TOOL - 30

Stores code Description020331Y Digital multimeter

020357Y 32x35 mm punch

020359Y 42 x 47 mm punch

020360Y Adaptor 52x54 mm

020363Y Crankshaft oil seal punch D 20 mm

020368Y driving pulley lock wrench

Tooling

TOOL - 31

Stores code Description020375Y 28x30 mm punch

020376Y Adapter handle

020382Y Tool for removing valve cotters fitted withpart 012

020382Y011 adaptor for valve removing tool

020393Y Piston fitting ring

020412Y Clutch oil seal punch D 15 mm

Tooling

TOOL - 32

Stores code Description020423Y Driven pulley lock wrench

020424Y Punch for fitting driven pulley roller casing

020425Y Punch for flywheel side oil seal

020430Y Tool for fitting the pin snap rings

020434Y Fitting for oil pressure check

020444Y011 adaptor ring

Tooling

TOOL - 33

Stores code Description020444Y009 46 x 55 wrench


020442Y Pulley lock wrench

020444Y Tool for fitting/removing the clutch on thedriven pulley

020455Y 10-mm guide for oil seal on water pumpshaft

020456Y Ø24 mm adaptor

Tooling

TOOL - 34

Stores code Description020454Y Tool to fit pin snap rings (200 - 250)

020477Y 37-mm Adaptor

020483Y 30 mm guide

020489Y Stud bolt set for hub cover support

Tooling

TOOL - 35

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance chart

ROUTINE MAINTENANCE TABLE

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARYC: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE* Check level every 3,000 km** Replace every 2 years*** Replace every 4 years

km x 1,000 1 6 12 18 24 30 36 42 48 54 60Driven pulley roller casing L L L L LSafety locks I I I I I ISpark plug I R I R I R I R I Rdriving belt I R I R I R I R I RThrottle control A A A A A ABrake disc I I I I I I I I I I IAir filter C C C C C C C C C CSAS filter C C C C CEngine oil filter R R R R R R R R R R RValve clearance A A A AElectrical system and battery I I I I I I I I I I IBraking systems I I I I I I I I I I ILight circuit I I I I I I I I I I IBrake control levers L L L L L LBrake fluid ** I I I I I I I I I I ICoolant level** I I I I I I I I I I IExhaust muffler/ silencer I I I I IEngine oil* R R R R R R R R R R RHub oil R I I I R I I I R I IHeadlight aiming adjustment A A A A ABrake pads I I I I I I I I I I ISliding blocks / Variable speed rollers I R I R I R I R I RVehicle test drive I I I I I I I I I I IRadiator C C CIdle speed A A A A A AWheels/tyres I I I I I I I I I I ISuspensions I I I I ISteering I I I I I ITransmissions L L L L LFuel pipes *** I I I I I I I I I I

Spark plugCAUTION

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.

Check and/or replace the spark plug at the intervals shown in the scheduled maintenance table. To

reach the spark plug:

Remove the central cover of the chassis.

Undo the indicated screw and remove the spark plug inspection cover.

Maintenance

MAIN - 37

Disconnect the tube.

Unscrew the spark plug.

CharacteristicSpark plug electrode gap

0.7 -0.8 mm

Spark plug

NGK CR7EB

To refit, carry out removal operations but in reverse order

Hub oil

Ride a few kilometres until the regular working temperature is reached, then shut off the engine.NOTE

USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE.

Check

Park the vehicle on firm and level

ground.

Rest the vehicle on its centre stand.

Unscrew and pull out the measuring

cap-dipstick.

Clean the area in contact with oil with

a clean cloth.

Screw the cap-dipstick fully down into

its tube.

Pull out the cap-dipstick again and

read the level the oil reaches on the

dipstick.

The level is correct when it is close to

the first notch above the little round

mark.

Top-up if necessary.CAUTIONWAIT SOME MINUTES UNTIL THE ENGINE AND THE EX-HAUST SYSTEM ARE COLD.

TOP-UP

Pour a small quantity of oil through the fill opening and wait about one minute so that the oil

flows evenly into the crankcase.

Maintenance

MAIN - 38

Check the oil level and top up, if required.

Top-up with small quantities of oil, until the recommended level is reached.

At the end of the operation, screw and tighten the cap-dipstick.NOTE

RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC-OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS ANDCAN CAUSE IRRETRIEVABLE DAMAGE

Replacement

Park the vehicle on firm and level ground.


Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and

cool down.CAUTION


Unscrew and pull out the measuring

cap-dipstick.

Place a +300 cm³ (18.3 cu.in) capacity

container under the drain screw. Un-

screw and remove the drain screw and

let the oil drain off completely.

Screw and tighten the drain screw.

Add oil through the transmission oil fill

opening.

Screw and tighten the measuring cap-

dipstick.

Start the engine and let it run for sev-

eral minutes. Stop the engine and let it

cool down.

Check the transmission oil level.CAUTIONUSED OIL CONTAINS SUBSTANCES THAT ARE HARM-FUL TO THE ENVIRONMENT. DISPOSE OF USED OIL AC-CORDING TO THE REGULATIONS IN FORCE.

Maintenance

MAIN - 39

Air filter

Clean and check the air filter following the indications specified in the scheduled maintenance table.

Carry out the maintenance procedures more frequently if the vehicle is used in rainy or dusty areas, or

off road. In this case, the air filter can be partially cleaned after travelling along these kinds of roads.CAUTION

PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACE-MENT.DO NOT START THE ENGINE WITHOUT THE AIR FILTER.DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FILTERING ELEMENT; THE FUEL SUPPLYSYSTEM MAY CATCH FIRE POSING A GREAT RISK FOR PEOPLE AND THE VEHICLE ITSELF.

Remove the filter.

Wash the filtering element with clean,

non-flammable or high-volatility sol-

vents, and let it dry properly.

Apply a specific filter oil over all the

surface.CAUTIONPARTIAL AIR FILTER CLEANING DOES NOT EXCLUDENOR POSTPONE AIR FILTER REPLACEMENT.DO NOT START THE ENGINE WITHOUT THE AIR FILTER.DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FIL-TERING ELEMENT; THE FUEL SUPPLY SYSTEM MAYCATCH FIRE POSING A GREAT RISK FOR PEOPLE ANDTHE VEHICLE ITSELF.

Check the lower part of the bleed pipes «1» for dirt.

Remove any deposit coming from the filter housing found inside the bleed pipe. Proceed as follows:

Remove the caps «2».

Drain the content in a container; then, send it to a recycling bank.WARNING

NEVER REUSE A FILTER.

Replace the air filter with a new one of the same type.

Engine oil

Maintenance

MAIN - 40

Replacement


Shut off the engine and let it cool down,

so that the crankcase oil drains out and

cools off.

Unscrew and pull out the cap-dipstick

«1».

Place a container under the filter to col-

lect the engine oil.

NOTEPARK THE VEHICLE ON SAFE AND LEVEL GROUND.CAUTIONWAIT SOME MINUTES UNTIL THE ENGINE AND THE EX-HAUST SYSTEM ARE COLD.

Unscrew and remove the cartridge en-

gine oil filter «4».

Unscrew and remove the oil drainage

plug «3» and then drain all the engine

oil into the collecting container.

Fit a new oil cartridge filter «4» and

take special care to lubricate the filter

sealing O-rings with oil.

Screw and tighten the engine oil drain-

age plug «3».

Add oil through the transmission en-

gine oil fill opening.

Screw and tighten the measuring cap-

dipstick «1».

Start the engine and let it run for sev-

eral minutes.

Stop the engine and let it cool down.

Check the engine oil level.CAUTIONUSED OIL CONTAINS SUBSTANCES THAT ARE HARM-FUL TO THE ENVIRONMENT. DISPOSE OF USED OIL AC-CORDING TO THE REGULATIONS IN FORCE.

Check

Park the vehicle on firm and level ground.


Maintenance

MAIN - 41

CAUTION


Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down.NOTE

FAILURE TO FOLLOW THESE OPERATIONS MAY RESULT IN AN INCORRECT READING OFTHE ENGINE OIL LEVEL.

Unscrew and take out the measuring

cap-dipstick «1».

Clean the area in contact with oil with

a clean cloth.

Screw the cap-dipstick «1» fully down

into its tube «2».

Pull out the cap-dipstick again «1» and

read the level the oil reaches on the

dipstick:

MAX = maximum level.

MIN = minimum level.

The level is correct when it is close to

"MAX" level, marked on the measuring

dipstick.

Top up if necessary.WARNINGDO NOT GO BEYOND THE "MAX" OR BELOW THE "MIN"LEVEL MARKS TO AVOID SEVERE ENGINE DAMAGE.

ENGINE OIL TOP-UP

Pour a small quantity of oil through the fill opening «2» and wait about one minute so that

the oil flows evenly into the crankcase.

Check the oil leveland top-up,if required.

Top-up with small quantities of oil, until the recommended level is reached.

At the end of the operation, screw and tighten the cap-dipstick «1».

NOTE

RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC-OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS ANDCAN CAUSE IRRETRIEVABLE DAMAGE.NOTE

DO NOT EXCEED THE "MAX" MARK WHEN TOPPING-UP ENGINE OIL.

Cooling system

Level checkCAUTION

Maintenance

MAIN - 42

WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANTLEVEL.CAUTION

PARK THE VEHICLE ON SAFE AND LEVEL GROUND.

Shut off the engine and wait until it

cools off.

Undo the indicated screw on both sides

and remove the front case.

Make sure that the liquid level in the

expansion tank is between "MIN" and

"MAX" references.

Otherwise, top-up.

DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TOTHE OIL.

TOP-UP

Loosen but do not remove the coolant reservoir cap.

Wait for some seconds so that possible pressure may be purged.

Unscrew and remove the cap

Top up with the recommended product until the liquid approximately reaches the "MAX"

level.

Refit the fuel tank cap.CAUTION

IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANKREMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT.

Radiator cleaning

Remove the front case.

Wash the radiator with a pressurised water jet.

Blow the radiator with compressed air.NOTE

IT IS NOT NECESSARY TO REMOVE THE RADIATOR

Maintenance

MAIN - 43

Braking system

The following operations refer to both braking systems.CAUTION

PURGE THE AIR IN THE SYSTEM IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER,EXCESSIVE ELASTICITY OR AIR BUBBLES IN THE CIRCUIT.DO NOT USE OR MIX DIFFERENT SILICON- OR PETROLEUM-BASED COOLANT TYPES.PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIR-CUIT.

Level check

Park the vehicle on its centre stand.

Turn the handlebar so that the fluid in

the brake fluid reservoir is parallel to

the «MIN» reference mark indicated on

the sight glass «1».

Check that the level in the reservoir is

over the «MIN» reference mark indica-

ted on the sight glass «1».

MIN = minimum level.

If the fluid does not reach at least the «MIN» ref-

erence mark:CAUTIONBRAKE LEVEL DECREASES GRADUALLY AS BRAKEPADS WEAR DOWN.

• Check brake pads and disc for wear. If the pads and/or the disc do not need replacing, top-up the

fluid.

Top-up

Remove the front handlebar cover.

Undo and remove the four screws in-

dicated.CAUTIONRISK OF BRAKE FLUID SPILLS. DO NOT PULL THEFRONT BRAKE LEVER WHEN THE SCREWS ARE LOOSEOR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COV-ER HAS BEEN REMOVED. PLACE A CLOTH UNDER THEBRAKE FLUID RESERVOIR TO PROTECT IT FROM ANYFLUID LEAKS.

Maintenance

MAIN - 44

Remove the cover and top up the res-

ervoir with the recommended liquid un-

til the correct level is reachedCAUTIONDO NOT SHAKE THE VEHICLE TO AVOID BRAKE FLUIDSPLASHING DURING TOP-UP.CAUTIONAVOID PROLONGED AIR EXPOSURE OF THE BRAKEFLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBSMOISTURE WHEN IN CONTACT WITH AIR. LEAVE THEBRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIMENEEDED TO COMPLETE THE TOPPING UP PROCEDURE.CAUTIONDO NOT FILL UP THE TANK TO THE MAXIMUM, BUT JUSTOVER THE ''MIN'' LEVEL. TOP-UP TO MAXIMUM LEVELMARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE LEV-EL DECREASES GRADUALLY AS BRAKE PADS WEARDOWN. IT IS ADVISABLE NOT TO TOP-UP TO THE MAXLEVEL MARK WHEN THE BRAKE PADS ARE WORN BE-CAUSE YOUR RISK SPILLING FLUID WHEN CHANGINGTHE BRAKE PADS.

Headlight adjustment

For a quick check of the correct direction of the

front light beams, place the vehicle ten metres

from a vertical wall and make sure the ground is

level.

Turn on the low-beam light, sit on the vehicle and

check that the light beam projected to the wall is a

little below the headlight horizontal straight line

(about 9/10 of the total height).

To adjust the light beam:

Use a screwdriver to act on the corre-

sponding screws «1» on the front

wheel housing.

SCREW it (clockwise) to raise the light beam.

UNSCREW it (anticlockwise) to lower the light

beam.

Maintenance

MAIN - 45

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

KEY:

1. Multiple connectors

2. Fuel Level Sensor

3. Instrument panel

4.Thermistor

5.Speed sensor

6. MODE Button

7. Horn

8. Key switch

9. Front stop switch

10. Rear stop switch

11.Light switch

12. Left rear turn indicator

13. Twin tail light/stop light bulb

14. Right rear turn indicator

15. Rear light assembly

16. License plate light

17. Stop light relay

18. Turn indicators switch

19. Start-up relay

Electrical system

ELE SYS - 47

20. Starter motor

21. Main fuses

22. Auxiliary fuses

23. Plug socket

24. Battery

25. HV coil

26. Spark plug

27. Automatic starter

28. CDI Control Unit

29. Connection for oil sensor (USA only)

30. Oil pressure sensor

31. Pick-up

32. Generator

33. Voltage regulator

34. Thermometric switch

35. Fan

36. Glove-box light

37. Glove-box light switch

38. Right front turn indicator

39. - Headlamp tail light

40. High-beam bulb

41. Low-beam bulb

42. Left front turn indicator

43. Complete front headlamp

44. Blinker (USA only)

45.Kit for blinker (USA only)

46. Horn button

47.Start button

48. Engine stop switch

CABLE COLOURS

Ar orange

Az sky blue

B blue

Bi white

G yellow

Gr grey

M brown

N black

Electrical system

ELE SYS - 48

R red

V green

Vi purple

Ro pink

Components arrangement

1. Fan

2. Thermometric switch

Remove the legshield to reach it.

Electrical system

ELE SYS - 49

3. Horn


Remove the front wheel housing to reach it.

Electric characteristicNo-load recharge voltage

13 ÷ 15 V at 5000 rpm

5. Battery

6. Fuses

Remove the battery cover on the footrest to reach

them.

7. Start-up relay

8. Stop light relay

Remove the footrest to reach it.

9. Speed sensor

It is placed on the rear wheel.

Electrical system

ELE SYS - 50

10. Magneto flywheel

11. Automatic starter

Remove the tail section to reach connectors.

Electric characteristicPermanent magnet generator

12V - 180W

Stator winding resistance

0.1÷1 Ohm at 20 °C (68 °F)

Off-load generated voltage

> 50 V at 5000 RPM

Pick-up winding resistance

105±10% Ohm at 20 °C (68 °F)

Starter resistance

~30 Ohm at 20 °C (68 °F)

12. Control unit

Remove the tail section to reach it.


Remove the plastic cover under the saddle to

reach it.

Electric characteristicFull tank

100±10% Ohm

Empty tank

1200±10% Ohm

Electrical system

ELE SYS - 51

14. Thermistor

Remove the helmet compartment to reach it.

Electric characteristicResistance at 100 °C (212°F)

144 Ohm

Resistance at 80 °C (176°F)

262 Ohm


512 Ohm


1090 Ohm

15. HV coil

Remove the rear central cover to reach it.

Electric characteristicSecondary resistance

2900±10% Ohm at 20 °C (68 °F)

Primary resistance

0.2±10% Ohm at 20 °C (68 °F)

Electrical system

ELE SYS - 52

Front side

Electrical system

ELE SYS - 53

Electrical system

ELE SYS - 54

KEY

1.Push through the hole

2. Long black clamps (290x4.5)

3.Push through the hole

Electrical system

ELE SYS - 55

KEY

1. Medium black clamps (180x4.5)

Electrical system

ELE SYS - 56

KEY


Electrical system

ELE SYS - 57

KEY

1. Long black clamps

Electrical system

ELE SYS - 58

KEY

1.Long black clamps (290x4.5)

Electrical system

ELE SYS - 59

Electrical system

ELE SYS - 60

Electrical system

ELE SYS - 61

KEY


Electrical system

ELE SYS - 62

Electrical system

ELE SYS - 63

Back side

KEY


Electrical system

ELE SYS - 64

KEY

1. Small black clamps (98x2.5)

Electrical system

ELE SYS - 65

KEY

1. Rubber cap

2.Medium black clamps (180x4.5)

Electrical system

ELE SYS - 66

KEY


Electrical system

ELE SYS - 67

KEY


2. Cable guide

Electrical system

ELE SYS - 68

KEY


Electrical system

ELE SYS - 69

KEY

1.Long black clamps (290x4.5)

Electrical system

ELE SYS - 70

KEY


Electrical system

ELE SYS - 71

KEY

1.Small black clamps (98x2.5)

Electrical system

ELE SYS - 72

KEY

1.Medium black clamps (180x4.5)

Electrical system

ELE SYS - 73

Conceptual diagrams

Ignition

KEY:

8. Key switch

21. Main fuses

22. Auxiliary fuses

24.Battery

25. HV coil

26.Spark plug


31. Pick-up


Electrical system

ELE SYS - 74

Battery recharge and starting

KEY:

8. Key switch

9.Front stop switch


19. Start-up relay

20. Starter motor

21. Main fuses

22. Auxiliary fuses

24. Battery

32. Generator


47. Start button


Electrical system

ELE SYS - 75

Level indicators and enable signals section

KEY:

1. Multiple connectors


3.Instrument panel

4.Thermistor

5.Speed sensor

8.Key switch

21. Main fuses

22. Auxiliary fuses

24.Battery

29. Connection for oil sensor (USA only)

30.Oil pressure sensor

Electrical system

ELE SYS - 76

Devices and accessories

KEY:

3.Instrument panel

6.MODE Button

7. Horn

8.Key switch

21. Main fuses

22. Auxiliary fuses

23. Plug socket

24. Battery

27.Automatic starter


34.Thermometric switch

35.Fan

46. Horn button

Electrical system

ELE SYS - 77

Lights and turn indicators

KEY:

3.Instrument panel

8.Key switch

9.Front stop switch


11. Light switch

12.Left rear turn indicator

13. Twin tail light/stop light bulb

14. Right rear turn indicator

15.Rear light assembly

16.License plate light

17. Stop light relay

18. Turn indicator switch

21. Main fuses

22. Auxiliary fuses

24.Battery

28.CDI Control Unit

38.Right front turn indicator

Electrical system

ELE SYS - 78

39. -Front headlamp tail light

40. High-beam bulb

41. Low-beam bulb

42. Left front turn indicator

43.Complete front headlamp

44. Blinker (USA only)

45. Kit for blinker (USA only)

48.Engine stop switch

Checks and inspections

Ignition circuit

No spark plugCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-CONNECTED.

Check spark plug for correct conditions, clean it

and remove deposits. Replace it, if necessary.

Pick-Up Check

With engine off disconnect the control

unit connector.

Measure the resistance present be-

tween terminals No. 6 (Blue-Yellow ca-

ble) and No. 8 (Blue cable).

If the value measured is incorrect, re-

peat the check directly on the compo-

nent.

Electrical system

ELE SYS - 79

Disconnect the Pick-Up connector and

measure the resistance between the

pin corresponding to the Blue-Yellow

cable of the wiring and the ground con-

nection on the engine.

If the value measured is correct, check

wiring continuity.

Electric characteristicPick-up winding resistance

105±10% Ohm at 20 °C (68 °F)

Coil primary check:

Disconnect the connector of the control

unit.

Measure the resistance present be-

tween terminals No. 3 (White-Purple

cable) and No. 8 (Blue cable).

If the measured value is incorrect, re-

peat the check between the positive

and negative terminals of the coil.

If a correct value is measured, check

wiring continuity.

Electric characteristicPrimary resistance

0.2±10% Ohm at 20 °C (68 °F)

Coil secondary check

Disconnect the spark plug cap from the

coil cable and measure the resistance

between the cable end and the coil

green negative terminal.

Electric characteristicSecondary resistance

2900±10% Ohm at 20 °C (68 °F)

Battery recharge circuit

With engine running at high revs, measure the voltage present at the battery poles.

Electric characteristicNo-load recharge voltage

Electrical system

ELE SYS - 80

13 ÷ 15 V at 5000 rpm

Stator check

Checking the stator windingWARNING

THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Remove the front wheel housing.

2) Disconnect the voltage regulator connector.

3) Measure the resistance between each of the

yellow terminals and the other two.

Electric characteristicStator winding resistance

0.1÷1 Ohm at 20 °C (68 °F)

4) Check that there is insulation between the each

yellow cable and the earth.

5) If incorrect values are detected, repeat the

check directly on the stator and control cable har-

nesses if necessary.

Recharge system voltage check

Connect the ammeter induction clamp

to the voltage regulator positive termi-

nal (Red-Orange).

Measure the battery voltage and turn-

ing on the vehicle lights, with engine

off, wait for the voltage to set at about

12 V.

Start the engine and measure the cur-

rent generated by the system with

lights on and a high running engine.

CharacteristicGenerated current:

³ 6A at 6000 rpm

Electrical system

ELE SYS - 81

Start up system check

KEY:

1. Key switch

2.Front stop switch

3.Rear stop switch

4. Start button

5.Engine stop switch

6. Start-up relay

7. Starter motor

8.Battery

9. Main fuses

10. Auxiliary fusesCAUTION


Electrical system

ELE SYS - 82

1) Check fuses No. 1 and 4.

2) Check key switch and engine stop switch con-

tacts.

3) Check stop switches and start button contacts.

4) Try to start up and check for voltage between

the Yellow-Red cable and the Blue cable of the

start-up relay (see figure).

5) If voltage is not detected, check cable harness

continuity.

6) Check the start-up relay.

7) Check the integrity and the connections of the

Red cable that connects the battery to the start-up

relay.

8) Repeat the check with the Red cable that con-

nects the start-up relay and the starter motor (see

figure).

Horn control

KEY:

1. Horn button

Electrical system

ELE SYS - 83

2. Key switch

3. Horn

4.Battery

5.Main fuses

6.Auxiliary fusesCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-CONNECTED.1) Check fuses No. 1 and 3.

2) Check key switch and horn button contacts.

3) With the key switch set to «ON», check for volt-

age between the Green cable of the horn button

and ground. If voltage is not detected, check cable

harness continuity.

4) Check the integrity and the connections of the

Grey cable of the horn and the horn ground lead

(Blue cable).

Choke Inspection

KEY:

1.CDI Control Unit

Electrical system

ELE SYS - 84

2. Key switch

3.Main fuses

4.Battery

5.Auxiliary fuses

6.Automatic starterCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-CONNECTED.1) Keep the connector connected to the system

and check for voltage between both terminals of

the starter when the engine is on.

2) If no voltage is detected, check the continuity of

the Green-Red cable with fuse No. 4 and that of

the Green-Black cable with the control unit (pin 7).

Electric characteristicStarter resistance

~30 Ohm at 20 °C (68 °F)

Turn signals system check

KEY:

1. Instrument panel

Electrical system

ELE SYS - 85

2.Turn indicators switch

3. Left rear turn indicator

4.Right rear turn indicator

5.CDI Control Unit

6.Right front turn indicator

7.Left front turn indicatorCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-CONNECTED.1) Check that bulbs and their ground connection are in working conditions (Blue cables).

2) Check the continuity of the Blue-Black cable connecting the control unit (pin 1) and the turn indicator

switch.

3) Check the contacts of the turn indicator switch.

4) Check the integrity and the connections of the bulbs cable harnesses (Sky blue and Red cables) to

the turn indicator switch.

level indicators

KEY:

1.Fuel Level Sensor

2.Instrument panelCAUTION

Electrical system

ELE SYS - 86


1) Measure the resistance in the fuel level sensor

ends in the different conditions.

2) If the resistance values are correct, but the in-

dication on the instrument panel is incorrect, check

the integrity and the connections of the cable har-

nesses (Brown cable with pin 7 of the instrument

panel connector and Grey-Green cable with pin 12

of the instrument panel connector.)

Electric characteristicFull tank

100±10% Ohm

Empty tank

1200±10% Ohm

Lights list

KEY:

1.Instrument panel

2. Light switch

Electrical system

ELE SYS - 87

3.Key switch

4.Twin tail light/stop light bulb

5.License plate light

6. Battery

7. Main fuses

8.Auxiliary fuses

9. High-beam bulb

10. Front headlamp tail lights

11.Low-beam bulb

BULBS/WARNING LIGHTSSpecification Desc./Quantity

1 High-/low-beam bulb 12 V - 55 W - H72 Tail light bulb 12V - 5W3 Front turn indicator bulbs 12 V - 10 W (Amber)4 Rear turn indicator bulbs 12 V - 10 W (White)5 Rear tail light /stop light bulb 12 V - 5/21 W (Red)6 License plate light bulb 12V - 5W7 Instrument panel lighting bulb LED8 Turn indicator warning light LED9 High-beam warning light LED10 Low fuel warning light LED11 Engine oil pressure warning light LED12 High coolant temperature gauge warning light LED

CAUTION


Tail lights line check

1) Check that bulbs and their ground connection are in working conditions (Blue cables).


3) Check key switch contacts.

4) Check the integrity and the connections of the bulbs cable harnesses (Green cables) with fuse No.

3.

High-beam/low-beam lights line check

1) Check that bulbs and their ground connection are in working conditions (Blue cables).


3) Check key switch and light switch contacts.

4) With the key switch set to «ON», check for voltage between the light switch Green cables and ground.

If voltage is not detected, check cable harness continuity.

5) Check that the connections between bulb cable harnesses (White cable and Black cable) and the

light switch are in good conditions.

Electrical system

ELE SYS - 88

FusesCAUTION

DO NOT REPAIR FAULTY FUSES.NEVER USE FUSES OTHER THAN THE ONES SPECIFIED.A SHORT CIRCUIT MAY DAMAGE THE ELECTRICAL SYS-TEM OR EVEN CAUSE A FIRE.NOTEIF THE SPARE FUSE IS USED, REPLACE WITH ONE OFTHE SAME TYPE IN THE CORRESPONDING FITTING.

FUSE DISTRIBUTIONSpecification Desc./Quantity

1 Fuse No. 1 Capacity: 20AProtected circuits: Key switch, instrument panel, fan

and recharge circuit.2 Fuse No. 2 Capacity: 15 A

Protected circuits: From battery to plug socket.3 Fuse No. 3 Capacity: 15 A

Protected circuits: From key switch to tail lights, stoplights, high-beam light, low-beam light, horn and instru-

ment panel.4 Fuse No. 4 Capacity: 7.5A

Protected circuits: From key switch to automatic start-er, ignition and start-up circuit.

Dashboard

KEY

1. Blue high-beam warning light

2. Green turn indicators warning light

3. Fuel gauge

4. Orange low fuel warning light

Electrical system

ELE SYS - 89

5. Speedometer

6. Coolant high temperature warning light

7. Coolant temperature gauge

8. Red oil pressure warning light.

9. ABS warning light (Activated on ABS versions only)

10. Multifunction indicator: total odometer (ODO) / two trip odometers (ODO I - ODO II) / battery voltage

11. Warning light not active

12. Digital clock

Km or miles selection

Quickly press the MODE button, select the battery voltage measurement function. Hold down the MODE

button for more than 10 seconds to change from km to mile reading for the odometer.

For the first 5 seconds the button is held down, there will be no instrument panel indication, but for the

next 5 seconds, the legend of the unit of measurement (km or miles) currently in use will flash at a

frequency of 1 Hz. If the button is released before 10 seconds elapse, the unit of measurement does

not vary.

Data check functionWARNING

THE SERVICE WARNING LIGHT IS NOT ACTIVE. WHEN THE KEY IS INSERTED, THE SERVICECOUPONS ICON SHALL BE ON FOR TWO SECONDS ONLY AFTER REACHING 50,000 KM. CAR-RY OUT THE RESET SERVICE TO ELIMINATE THE SERVICE COUPONS ICON IGNITION.

RESET

Hold the MODE button down.

Turn the key to ''ON'' and wait 10 seconds.

During this operation the service icon flashes at a

1 Hz frequency.

Electrical system

ELE SYS - 90

Sealed battery

Commissioning sealed batteries (without maintenance)

In case the vehicle fits a sealed battery, the maintenance is limited to the loading state and to an eventual

recharge. 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 scooter and afterwards every

6 months.

INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE

1. Voltage check

2. Before installing the battery on the vehicle, check the open circuit voltage with a standard

tester.

If voltage is over 12.60V, the battery can be installed without any refresh.

If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

3. Constant-voltage battery charge mode

4. Constant-voltage charge equal to 14.40÷14.70V

Initial charge current equal to 0.3÷0.5 of the battery rated capacity

Charge time:

10 to 12 h recommended Minimum 6 h Maximum 24 h

5. Constant-current battery charge mode

6. Charge current equal to 1/10 of the battery rated capacity

Dry-charge battery

Commissioning dry charge battery (with maintenance)WARNING

BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINSSULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF IT ACCIDEN-TALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATERFOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORMILK FOLLOWED BY MAGNESIUM MILK, BEATEN EGG OR VEGETABLE OIL. SEEK IMMEDIATEMEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS ORCIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.KEEP OUT OF THE REACH OF CHILDREN

Electrical system

ELE SYS - 91

Remove the short closed tube and the

caps, then pour sulphuric acid into the

cells, using the type specified for bat-

teries, with a specific gravity of 1.26,

corresponding to 30° Bé, at a minimum

temperature of 15°C until the upper

level is reached.

Leave to rest for at least 2 hours, then

restore the level with sulphuric acid.

Within the following 24 hours, recharge

with the specific battery charger at an

intensity of about 1/10 of the battery

nominal capacity and until the acid

density is about 1.27, corresponding to

31º Bé, and these values are stabi-

lised.

Once the charge is complete, level the

acid (by adding distilled water). Close

and clean carefully.

Once the above operations have been

performed, install the battery on the ve-

hicle ensuring that it is connected prop-

erly.

1 Hold the tube upright

2 Inspect visually

3 The float must be freed

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.

Charge status check

After topping-up the electrolyte level, check its density using an appropriate densitometer.

With the battery charged, a density of 30÷32 Bé, corresponding to a specific weight of 1.26÷1.28, must

be at a minimum temperature of 15° C.

A density reading below 20° Bé indicates that the battery is completely flat and must therefore be

recharged.

If the vehicle is not be used for a certain time (1 month or more), the battery needs to be recharged

periodically.

Electrical system

ELE SYS - 92

The battery runs down completely in about three months. Should the battery be fitted on a vehicle, be

careful not to invert the connections, keeping in mind that the (black) ground wire marked (-) is con-

nected to the - negative terminal while the other two red wires marked (+) are connected to the +

positive terminal.

Battery rechargeWARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP NAKEDFLAMES OR SPARKS AWAY FROM THE BATTERY WHILE CHARGING.

First detach the negative terminal before removing the battery from the vehicle.

Normal bench charging must be performed using the special battery charger, setting the battery charge

selector to the type of battery that requires recharging (that is, at a current equal to 1/10 of the battery

rated capacity). Connections to the power supply source must be implemented by connecting corre-

sponding poles (+ to + and - to -).

The battery should always be kept clean, especially its top side, and the terminals should be coated

with petroleum jelly.CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USINGA FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSEA FIRE.CAUTION

ORDINARY DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL TO THE BAT-TERY. CONSEQUENTLY, ONLY USE DISTILLED WATER.CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY BEFORE BEING PUT INTO OPERATION SHORT-ENS BATTERY LIFE.

Electrical system

ELE SYS - 93

Connectors

ENGINE CONNECTOR

1. Stator phase (Yellow)

2.Not connected

3.Stator phase (Yellow)

4. Oil pressure sensor (Purple)

5.Stator phase (Yellow)

6.Pick-up (Blue-Yellow)

VOLTAGE REGULATOR CONNECTOR

1. Magneto flywheel (Yellow)

2.Magneto flywheel (Yellow)

3.Magneto flywheel (Yellow)

4. Battery positive (Red-Orange)

5. Not connected

6. Ground (Blue)

ECU

1.Turn indicators switch (Blue-Black)

2.Not connected

3.HV coil (White-Purple)

4.Not connected

5.Live supply (White-Black)

6.Pick-up (Blue-Yellow)

7.Automatic starter (Green-Black)

8.Ground (Blue)

Electrical system

ELE SYS - 94

Dashboard

1.Oil pressure sensor (Purple)

2. MODE Button (Pink)

3. Left turn indicator warning light (Sky Blue)

4. Right turn indicator warning light (Red)

5.High-beam warning light (White)

6. Not connected

7. Fuel level sensor (Brown)

8. Speed sensor negative (Yellow-White)

9. Not connected

10. Speed sensor positive (Orange-Black)

11. Not connected

12. Fuel level sensor (Yellow-Green)

13.Thermistor (White-Blue)

14. Speed sensor signal (Blue-Orange)

15. Not connected

16. Ground (Blue)

17. Ground (Blue)

18. Not connected

19. Live supply (Green)

20. Battery-powered (Red-Orange)

Electrical system

ELE SYS - 95

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. RemovalCAUTION

ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF.

Remove the rear central cover.

Undo and remove the two fixing nuts of

the exhaust manifold

Undo and remove the three fixing

screws of the exhaust silencer.

Remove the exhaust system.

Silencer removal


Loosen the clamp (1) fixing the exhaust

silencer to the manifold.


screws (2).

Remove exhaust silencer.

Removal of the engine from the vehicle

Remove the saddle.

Remove the luggage rack.

Remove the side fairings.

Remove the tail section.

Remove the helmet compartment.

Engine from vehicle

ENG VE - 97

• Remove the rear brake calliper and release the

pipes from the engine by unscrewing the indicated

screw.

Remove the speed sensor by undoing

the fixing screw.

Remove the spark plug tube.

Remove the pipe connecting the radi-

ator to the water pump and empty the

system.

Engine from vehicle

ENG VE - 98

Remove the fuel inlet and delivery

pipes from the fuel pump.

Remove the fuel manifold from the car-

burettor.

Remove the coolant temperature sen-

sor connector.

Remove the starter motor power sup-

ply cable and the ground lead to re-

lease cable harnesses.

Engine from vehicle

ENG VE - 99

Remove the automatic starter connec-

tor and the generator connector.

Remove the throttle grip transmission

and release it.

Loosen the swinging arm fixing nut in

the engine.

Slide off the pin and remove the engine

from the vehicle.

When refitting the engine onto the scooter, carry out the removal operations but in reverse

order and respect the tightening torques shown in the «Specifications» Chapter.

Check the engine oil level and, if necessary, top it up with the recommended type.

Fill up and bleed the cooling circuit.

Check the functioning of the accelerator and the electrical devices.CAUTION

Engine from vehicle

ENG VE - 100

PAY SPECIAL ATTENTION WHEN POSITIONING THE THROTTLE CONTROL TRANSMISSIONPROPERLY.

Engine from vehicle

ENG VE - 101

INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools required.

Automatic transmission

Transmission cover

- To remove the transmission cover, it is necessary to remove the plastic cover first by inserting a

screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven

pulley shaft nut and washer.

Specific tooling

020423Y Driven pulley lock wrench

- Pull out the cap/dipstick from the engine oil filling tube.

- Remove the 10 screws.

- Now remove the transmission cover.

If this operation is carried out directly on the vehicle, remove the cooling air supply sleeve of the trans-

mission housing.

Engine

ENG - 103

Air duct

125 VERSION

Remove the 4 screws and the small casing.

200 VERSION

- Remove the 5 screws on the two different levels, as well as the small casing

Engine

ENG - 104

Air duct filter

To remove the intake throat on the transmission

cover, just remove the 2 fixing screws indicated in

the figure.

Removing the driven pulley shaft bearing

- Remove the Seeger ring from the inside of the

cover.

- Remove the bearing from the crankcase by

means of:

Specific tooling


020375Y 28 x 30 mm adaptor

020412Y 15 mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase internal side so as not

to damage the coated surface.

- Insert the bearing in its housing.

- Refit the Seeger ring.CAUTIONREST THE COVER ON A SUITABLE SURFACE TO AVOIDDAMAGING THE COVER COAT.NOTEALWAYS REPLACE THE BEARING WITH A NEW ONE ATEVERY REFIT

Specific tooling



020412Y 15 mm guide

Baffle roller

Removal

Belt support roller (only 200 cc version)

Engine

ENG - 105

- Check that the roller shows no signs of abnormal wear and that it rotates freely.

- Remove the special fixing screw and the roller with the bearing.

Refitting

- Heat up the roller and insert the bearing by using the specific punch:

Specific tools:

Specific tooling020455Y 10 mm guide

Engine

ENG - 106

- Refit the roller with the special screw.

- Tighten to the specified torque.

- Refit the intake throat with the O-Ring, the sealing gasket for the sump and the closing casing for the

fan.

Locking torques (N*m)Anti-vibration roller 12 ÷ 16

Removing the driven pulley

- Remove the spacer, the clutch bell and the whole

driven pulley assembly.NOTETHE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THEDRIVING PULLEY IS MOUNTED.

Inspecting the clutch drum

Checking the bell working surface eccentricity

- Fit the bell on a driven pulley shaft with 2 bearings (inside diameter: 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to check the crankshaft alignment.

- Make sure that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.

Characteristic

Engine

ENG - 107

Clutch bell max. value

Max. value: Ø 134.5 mm

Clutch bell standard value

Standard value: Ø 134 ÷ 134.2 mm

Inspecting the clutch

- Check the thickness of the clutch mass friction material.

- The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals.NOTE

UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUSTNOT BE DIFFERENT FROM ONE ANOTHER.DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING.CAUTION

DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID VARIATION IN THE RETURN SPRINGLOAD.

CharacteristicCheck minimum thickness

1 mm

Engine

ENG - 108

Removing the clutch

Removing the clutch (125cc H2O)

- Prepare the specific tool to compress the driven pulley spring with the medium-length pins in position

«F» screwed from the tool inner side.

- Insert the adaptor ring No. 8 in the pins.

- Fit the driven pulley unit on the tool by inserting the nail heads in the adaptor ring.

- Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the

clutch nut.

- With the specific 46x55 wrench, component No. 9, remove the clutch fixing nut.

- Disassemble the driven pulley into its components (Clutch, fan and spring with plastic fitting).CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST TOUCHTHE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.

Specific tooling

020444Y009 46 x 55 wrench


Engine

ENG - 109

- Prepare the specific tool to compress the driven pulley spring with the medium-length pins in position

«C» screwed from the tool inner side.

- Insert the adaptor ring No.11 with the chamfering facing the tool inner side.

- Fit the driven pulley unit on the tool by inserting the three pins in the ventilation holes in the ground

holder support.

- Make sure that the clutch is perfectly inserted into the adapter ring before carrying out the clutch nut

locking/release operations.

- With the specific 46x55 wrench, component No. 9, remove the clutch fixing nut.

- Disassemble the driven pulley into its components (Clutch and spring with plastic fitting).CAUTIONTHE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST TOUCHTHE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.Specific tooling020444Y009 46 x 55 wrench020444Y011 adaptor ring

Engine

ENG - 110

Pin retaining collar

- Simultaneously turn and pull the collar manually to remove it.NOTE

USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY.NOTE

BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGING THE O-RING SEAL.

Engine

ENG - 111

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noise; otherwise, replace it.

- Remove the snap ring using two flat blade screwdrivers.

- Place pulley bushing on the threaded side adequately on a wood support.

- Using a hammer and pin, knock the ball bearing out as shown in the figure.

- Properly support the pulley by means of the specific bell shown in figure.

Specific tooling

001467Y035 Bell for 47-mm outside diameter bearings

Engine

ENG - 112

- Remove the roller bearing using the modular punch.

Specific tooling


020456Y Ø24 mm adaptor

020363Y 20 mm guide

Inspecting the driven fixed half-pulley

- Measure the outside diameter of the pulley bushing.

- Check the contact surface with the belt to make sure there are no signs of abnormal wear.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

CharacteristicHalf-pulley minimum diameter

Minimum diameter allowed: Ø 40.96 mm

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm

Wear limit

0.3 mm

Engine

ENG - 113

Inspecting the driven sliding half-pulley

Remove the belt and slide off the movable half-pulley with the relative bushing, taking care

the free rollers fitted to it do not come out.

Remove the rollers support plate with the relative guide sliders.

Remove the 2 inner sealing rings and

the 2 O-rings.

Measure the inside diameter of the

movable half-pulley bushing.

CharacteristicMoving driven half-pulley max. diameter

Max. diameter allowed Ø 41.08 mm

Movable driven half-pulley standard diameter

Engine

ENG - 114

Standard diameter: Ø 41.000 ÷ 41.035 mm

Refitting the driven half-pulley bearing

- Place pulley bushing on the threaded side adequately on a wood support.

- Assemble a new roller casing as shown in the figure.

- To fit the new ball bearing, follow the example in the picture using the specific modular punch.

- Assemble the Seeger ringWARNINGNOTE

FIT THE BALL BEARING SO THAT THE SHIELD IS VISIBLE

Specific tooling



020424Y Punch for fitting driven pulley roller casing

Engine

ENG - 115

Refitting the driven pulley

Driven pulley assembly

- Insert the new oil seals and O-rings on the mov-

able half-pulley.

- Lightly grease the O-rings (A) shown in the figure.

- Fit the half-pulley on the bushing with the specific

tool

Check that the pins are not worn and proceed to

refit them in the relative hollows.--

- Refit the torque server closing collar.

- Using a curved-spout grease gun, lubricate the

driven pulley assembly with approximately 6

grams of grease. Apply the grease through one of

the holes in the bushing until grease comes out

through the hole on the opposite side. This proce-

dure is necessary to prevent the presence of

grease beyond the O-rings.NOTETHE TORQUE SERVER CAN BE GREASED WITH BEAR-INGS FITTED OR WHEN THEY ARE BEING REPLACED; ITMAY BE EASIER TO GREASE TORQUE SERVER WHENTHE BEARINGS ARE BEING SERVICED.

Specific tooling

020263Y Sheath for fitting the driven pulley

Recommended productsAGIP GREASE SM 2 Grease for C-ring of thetone wheel

Soap-based lithium grease with NLGI 2 molybde-

num disulphide; ISO-L-XBCHB2, DIN KF2K-20

- Insert the new oil seals and O-rings on the movable half-pulley.

- Lightly grease the O-rings «A» shown in the figure.

Engine

ENG - 116

Inspecting the clutch spring

- Measure the length of the movable driven half-

pulley spring, when unloaded.

CharacteristicStandard length (125)

106 mm

limit after use (125)

101 mm

Standard length (200)

123 mm

Limit after use (200)

118 mm

Refitting the clutch

125 VERSION

Support the specific tool to compress the driven pulley spring with the control screw in ver-

tical axis.

Prepare the tool with the medium-length screws in position «F», screwed from the inside.

Insert the adaptor ring No. 8 in the pins.

Preassemble the cooling fan to the clutch so that keying faces are aligned and the 3 heads

of the mass fulcrum pins «A» are fully visible.

Insert the clutch on the adaptor ring.

Lubricate the end of the spring that abuts against the torque server closing collar.

Insert the spring with the relative plastic support in contact with the clutch.

Engine

ENG - 117

Insert the driving belt in the pulley assembly observing the direction of rotation.

Insert the pulley assembly and the belt in the tool.

Preload the spring slightly.

Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to

tighten the clutch nut.

Place the tool in the vice with the control screw in horizontal axis.

Preload the spring fully.

Screw the clutch lock-nut and, with the specific 46x55 wrench, tighten it to the prescribed

torque.

Loosen the tool clamp and insert the belt observing the direction of rotation.

Lock again the driven pulley using the specific tool.

Preload the clutch return spring by turning and pulling alternately until maximum opening of

pulleys is reached and place the belt in the minimum diameter rolling position.

Remove the driven pulley / belt assembly from the tool.NOTE

FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACESHOULD BE MOUNTED CONTACTING THE CLUTCH.NOTE

WHEN PRELOADING THE SPRING, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRINGSTOP AND THE BUSHING THREADING.

Specific tooling


020444Y009 46 x 55 wrench

Locking torques (N*m)Clutch assembly nut on driven pulley 55 ÷ 60

Engine

ENG - 118

200 VERSION

Engine

ENG - 119

Support the specific tool to compress

the driven pulley spring with the control

screw in vertical axis.

Prepare the tool with the medium-

length screws in position «C», screwed

from the inside.

Insert the adaptor ring No. 11 with the

chamfering facing upwards.

Insert the clutch on the adaptor ring.

Lubricate the end of the spring that

abuts against the torque server closing

collar.

Insert the spring with the relative plas-

tic support in contact with the clutch.

Insert the driving belt in the pulley as-

sembly observing to direction of rota-

tion.

Insert the pulley assembly and the belt

in the tool.

Preload the spring slightly.

Make sure that the clutch is perfectly

inserted into the adapter ring before

proceeding to tighten the clutch nut.

Place the tool in the vice with the con-

trol screw in horizontal axis.

Preload the spring fully.

Screw the clutch lock-nut and, with the

specific 46x55 wrench, tighten it to the

prescribed torque.

Loosen the tool clamp and insert the

belt observing the direction of rotation.

Lock again the driven pulley using the

specific tool.

Preload the clutch return spring by

turning and pulling alternately and

place the belt in the smaller diameter

rolling position.

Engine

ENG - 120

Remove the driven pulley / belt assem-

bly from the tool.NOTEWHEN PRELOADING THE SPRING, BE CAREFUL NOT TODAMAGE THE PLASTIC SPRING STOP AND THE BUSH-ING THREADING.NOTEFOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-TED CONTACTING THE CLUTCH.

Specific tooling

020444Y Tool for fitting/removing the clutch onthe driven pulley


020444Y009 46 x 55 wrench

Locking torques (N*m)Clutch assembly lock-nut on driven pulley 55 ÷60 Nm

Refitting the driven pulley

- Refit the clutch bell and the spacer.

Drive-belt

During the wear check indicated in the scheduled

maintenance, it is recommended to check that the

rim bottom of the toothing does not show signs of

incisions or cracks «A». If it does, change the belt.

Removing the driving pulley

125 VERSION

Engine

ENG - 121

With the specific tool, remove the nut with the Belleville washer incorporated, the drive in

common with kick-starter versions and the steel washer.

Remove the fixed driving half-pulley.

Remove the steel washer of bushing separation.

Specific tooling


200 VERSION

Insert the specific tool in the internal slots to remove the nut with the built-in Belleville washer.

Specific tooling

020442Y Pulley lock wrench

Remove the start-up crown unit with the torque limiter.

Remove the fixed driving half-pulley with the O-ring and the steel washer in contact with the

bushing.

Engine

ENG - 122

Remove the belt and slide off the movable half-pulley with the relative bushing, taking care

the free rollers fitted to it do not come out.

Remove the rollers support plate with the relative guide sliders.

Check that the internal bushing shown

in the figure is not abnormally worn and

measure its inside diameter.

Measure the outside diameter of the

pulley sliding bushing shown in the fig-

ure.

Check that the rollers are not damaged

or worn.

Check that the guide sliders for the roll-

er contrast plate are not worn.

Engine

ENG - 123

Check that the roller housings or the

surfaces in contact with the belt on both

half-pulleys are not worn.

Check that fixed driving pulley does not

show signs of abnormal wear on the

grooved edge and on the surface in

contact with the belt.

Check that the O-Ring is not deformed.CAUTIONDO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristicroller (200): Minimum diameter admitted

Ø 20 mm

roller (125): Minimum diameter admitted

Ø 18.5 mm

sliding bushing: Minimum diameter admitted

Ø 25.95 mm

movable driving half-pulley bushing: Max. di-ameter admitted

Ø 26.12 mm

roller (200): Standard Diameter

Ø 20.5 ÷ 20.7 mm

roller (125): Standard Diameter

Ø 18.9 ÷ 19.1 mm

sliding bushing: Standard Diameter

Ø 25.959 ÷ 25.98 mm

movable driving half-pulley bushing: StandardDiameter

26.000 ÷ 26.021 mm

Refitting the driving pulley

125 VERSION

Refit the removed Bendix correctly on its seat.

Engine

ENG - 124

Refit the assembly components (inner shim washer, fixed half-pulley, outer shim washer,

drive,and nut), apply Loctite 243 "Super fast" threadlock on the thread and screw the nut to

the prescribed locking torque.

Prevent half-pulley rotation by using the stop wrench specific tool..

Turn the engine manually to obtain the minimum belt tension.CAUTION

WHEN ASSEMBLING THE FIXED DRIVING HALF-PULLEY, THE BELT MUST BE TOTALLY FREESO THAT THE PULLEY IS NOT INCORRECTLY TAUTENED.

Specific tooling


Locking torques (N*m)Driving pulley nut 75 ÷ 83

200 VERSION

Preassemble the movable half-pulley

with the roller contrast plate by placing

the rollers in their housings with the

larger support surface in contact with

the pulley according to the direction of

rotation.

Check that the roller contact plate does

not show flaws or is damaged on the

grooved edge.

Fit the entire bushing assembly on the

crankshaft.

Fit the driven pulley/Clutch/belt assem-

bly to the engine.

Engine

ENG - 125

Engine

ENG - 126

Refitting the transmission cover

- Check there are 2 centring dowels and that the sealing gasket for the oil sump has been adequately

fitted on the transmission cover.

- Replace the cover by tightening the 10 screws to the prescribed torque.

- Refit the oil filling cap dipstick.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the specified torque using the lock wrench and the torque wrench tools.

- Refit the plastic cover.

Specific tooling020423Y Driven pulley lock wrench

Locking torques (N*m)Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60

End gear

Removing the hub cover

- Empty the rear hub through the oil drainage plug.

Engine

ENG - 127

- Remove the 7 flanged screws indicated in the figure.

- Remove the hub cover and the relevant gasket.

Removing the wheel axle

- Remove the wheel axle with gear.

- Remove the intermediate gear.

Removing the hub bearings

- Check the status of the bearings being examined (wear, clearance and noise). If any fault is detected,

proceed as follows.

- Use the specific extractor to remove the three 15 mm bearings (2 on the crankcase and 1 on the hub

cover)

Specific tooling

001467Y013 Calliper to extract 15-mm diameter bearings

Engine

ENG - 128

Removing the wheel axle bearings

- Remove the Seeger ring from the outside of the hub cover.

- Support the hub cover and expel the bearing.

Remove the oil seal as shown in the figure by using the specific tools.

Specific tooling


020477Y 37-mm Adaptor

020483Y 30 mm guide

020359Y 42 x 47-mm adaptor

020489Y Stud bolt set for hub cover support

Engine

ENG - 129

Removing the driven pulley shaft bearing

- Should the driven pulley shaft, its bearing and oil guard be removed, take out the transmission cover

and the clutch assembly as described above.

- 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 on the belt transmission side.

- Remove the Seeger ring indicated in the figure

- Remove the driven pulley shaft bearing using the modular punch.

Specific tooling



020363Y 20 mm guide

Engine

ENG - 130

Inspecting the hub shaft

- Check the three shafts for wear or distortions on

the toothed surfaces, on the bearing housings and

the oil seal positions.

- In faults are found, replace the damaged parts.

Inspecting the hub cover

- Check that the coupling surfaces are not dented or distorted.

- Check the bearing capacity.

- In case of faults, replace the damaged parts.

Engine

ENG - 131

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- Warm the cover crankcase with the specific heat gun.

- Fit the wheel shaft bearing with a modular punch as shown in the figure.

- Fit the Seeger ring.

- Fit the oil guard with its sealing lip facing the hub internal side and place it flush with the internal surface

using the specific tool used on the 52-mm side .

The 52-mm side of the adaptor should face the bearing.

Specific tooling



020483Y 30 mm guide

Engine

ENG - 132

Refitting the hub cover bearings

- To fit the hub box bearings, the engine crankcase and the cover should be heated with the specific

heat gun.

- The three 15-mm bearings must be fitted using the appropriate tools:

The 42-mm side of the adaptor should face the bearing.

- Refit the driven pulley shaft bearing with a modular punch as shown in the figure.

- Refit the Seeger ring with the opening opposite to the bearing and the new oil guard levelled with the

crankcase on the pulley side.NOTE

USE THE STUD BOLT KIT TO SUPPORT THE COVER ADEQUATELY WHEN FITTING THE BEAR-ING ON THE COVER.NOTE

IF A BEARING WITH AN ASYMMETRICAL BALL RETENTION CAGE IS USED, PLACE IT SO THATTHE BALLS ARE VISIBLE FROM THE HUB INTERNAL SIDE.NOTE

WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, THE CRANKCASE SHOULD, ASFAR AS POSSIBLE, BE SUPPORTED ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIV-EN VERTICALLY.

Specific tooling

020150Y Air heater support

020151Y Air heater

020412Y 15 mm guide



020363Y 20 mm guide

Engine

ENG - 133

Refitting the hub bearings

- Assemble the 3 shafts in the engine crankcase as shown in the figure.

Engine

ENG - 134

Refitting the ub cover

- Fit a new gasket together with the centring dowels.

- Seal the gasket of the breather pipe using black silicone sealant.

- Fit the cover making sure the breather pipe is in the correct position.

- Position the 3 shorter screw, easily recognisable by its different colour, as shown in the figure.

- Fasten the breather pipe support bracket with the lower short screw.

- Fit the remaining 4 screws and tighten the 7 screws to the prescribed torque.

Locking torques (N*m)Rear hub cover screws 24 ÷ 27

Engine

ENG - 135

Flywheel cover

Removing the hub cover

- Remove both clamps, both sleeves and empty the cooling system.

- Remove the 4 retainers and the flywheel cover

Engine

ENG - 136

Removing the stator

- Remove the electric terminal of the minimum oil

pressure switch.

- Remove the two Pick-Up screws and the screw

holding the wiring support clamp and the 2 stator

fixing screws indicated in the figure.

- Remove the stator and its cable harness.

Refitting the stator

- Refit the stator and the flywheel carrying out the

removal steps but in reverse order, tightening the

retainers to the prescribed torque.

- Place the cable harness as shown in the figure.

- Stator and Pick-up statorNOTETHE PICK-UP WIRE SHOULD BE POSITIONED BETWEENTHE UPPER SCREW AND THE REFERENCE PIN ASSHOWN IN THE DETAILED DRAWING.

Locking torques (N*m)Stator unit screws (°) 3 ÷ 4

Refitting the flywheel cover

- Place the flywheel with the top dead center reference aligned with the crankcase reference.

- Prepare the flywheel cover by aligning references between the drive and the crankcase cover.

- Refit the cover on the engine by inserting the three stud bolts in the drive for the water pump.

- Follow the removal procedure but in reverse order.CAUTION

TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-TRING DOWELS ARE FITTED.

Engine

ENG - 137

Flywheel and starting

Removing the flywheel magneto

- Lock the Flywheel rotation using the calliper spanner tool.

- Remove the nut.

- Take out the flywheel.CAUTIONUSING A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STA-TOR COILS.NOTETHE 200CC VERSION FLYWHEEL IS SUPPLIED WITH MORE INERTIA MASS.

Engine

ENG - 138

Inspecting the flywheel components

- Check that the internal plastic parts of the flywheel and the Pick-Up control plate are in good conditions.

Refitting the flywheel magneto

- Fit the flywheel paying attention to insert the key

adequately.

- 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 fitting the

Pick-Up.

Different values result from deformations on the

Pick-Up support.NOTEA VARIATION IN THE AIR GAP DISTANCE MODIFIES THEIGNITION SYSTEM IDLE SPEED.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)Flywheel nut 54 ÷ 60

Engine

ENG - 139

Refitting the starter motor

- Fit and lubricate a new O-ring on the starter mo-

tor.

- Fit the starter motor on the crankcase and lock

the 2 screws to the prescribed torque.

Locking torques (N*m)Starter motor screws 11 ÷ 13

Cylinder assy. and timing system

Removing the intake manifold

- Remove the complete flywheel cover as descri-

bed in the flywheel cover chapter.

- Loosen the 3 screws and remove the air intake

manifold.NOTETHE 125 CC VERSION IS PROVIDED WITH TAMPER-PROOF SCREWS.

Removing the timing system drive

- First remove the parts listed below: transmission cover, driving pulley with belt, start-up pinion, oil

sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the pinion

separation washer.

- Remove the tappet cover.

- Remove the central screw fastener and the automatic valve-lifter retaining cover indicated in the figure.

- Remove the return spring of the automatic valve-lifter assembly, the automatic valve-lifter assembly

and its end of stroke washer.

- Loosen the central screw on the tensioner first.

- Remove the 2 clamps indicated in the figure.

- Remove the tensioner and its gasket.

- Remove the internal hex screw and the counterweight shown in the figure.

- Remove the camshaft control pulley and its washer.

- Remove the command sprocket wheel and the timing chain.

- Remove the screw indicated in the figure, the spacer and the tensioner pad.

Engine

ENG - 140

The tensioner pad must be removed operating from the transmission side. The lower chain guide pad

can only be removed after the head has been removed.NOTE

It is advisable to mark the chain in order to ensure that the original direction of rotation is maintained.

Engine

ENG - 141

Removing the cam shaft

Remove the 2 screws and the camshaft mounting bracket indicated in the figure.

Remove the camshaft.

Remove the pins and the rocking levers from the flywheel side holes.

Engine

ENG - 142

Removing the cylinder head

- Remove the spark plug.

- Remove the 2 side retainers indicated in the fig-

ure.

- Loosen the 4 head-cylinder fixing nuts in two or

three stages and in a criss-cross sequence.

- Remove the head, the 2 centring dowels and the

gasket.NOTEIF NECESSARY, THE HEAD MAY BE REMOVED TOGETH-ER WITH THE CAMSHAFT, ROCKING LEVER PINS ANDMOUNTING BRACKET. THE HEAD CAN ALSO BE RE-MOVED WITHOUT TAKING OUT THE CHAIN AND THECHAIN TIGHTENER OF THE CRANKSHAFT.

Removing the valves

- Using the appropriate tool fitted with an adapter, remove the cotter pins, plates, springs and valves.

- Remove the oil seals with the specific tool

- Remove the spring lower supports.

Engine

ENG - 143

CAUTION

ARRANGE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.

Specific tooling


020382Y Tool for removing valve cotters fitted with part 012


Removing the cylinder - piston assy.

- Remove the chain guide pad.

- Slide off the cylinder.

- Remove the gasket on the cylinder base.

- Remove the 2 Seeger rings, the pin and piston.

- Remove the piston sealing rings.CAUTION

TO AVOID DAMAGING THE PISTON, KEEP IT FIRM WHILE REMOVING THE CYLINDER.NOTE

BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.

Engine

ENG - 144

Inspecting the small end

- Measure the inside diameter of the small end using a specific micrometer.NOTE

REPLACE THE CRANKSHAFT IF THE ROD SMALL END DIAMETER EXCEEDS THE STANDARDDIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING.

CharacteristicChecking the rod small end: Max. diameter

15.030 mm

Checking the rod small end: Standard diameter

15+0.015 +0.025 mm

Engine

ENG - 145

Inspecting the wrist pin

Check the pin outside diameter.

Calculate the rod small end - pin cou-

pling clearance.

Measure the diameter of the bearings

on the piston.

Calculate the pin - piston coupling

clearance.NOTETHE PIN HOUSINGS HAVE TWO LUBRICATION CHAN-NELS FOR THIS REASON MEASURE THE DIAMETER AC-CORDING TO THE PISTON AXIS.

CharacteristicPin diameter: Standard clearance

0.015 ÷ 0.029 mm

Pin diameter: Standard diameter

14.996 ÷ 15.000 mm

Pin seat diameter on piston: Standard diame-ter

15.001 ÷ 15.006 mm

Pin seat diameter on piston: Standard clear-ance

0.001 ÷ 0.010 mm

Inspecting the piston

Carefully clean the sealing rings housings.

Measure the sealing rings - grooves coupling clearance using suitable sensors, as shown

in the diagram

Engine

ENG - 146

If clearances measured exceed the limits specified in the table, the piston should be replaced

by a new one. For coupling clearance data, see chapter "Check characteristics/data/As-

sembly clearances"

Engine

ENG - 147

Inspecting the cylinder

Using a bore meter, measure the cyl-

inder inside 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.

Maximum unevenness allowed: 0.05 mm

Pistons and cylinders are classified ac-

cording to their diameter. This coupling

is carried out in pairs (A-A, B-B, C-C,

D-D).

Cylinder grinding should be carried out

with a surfacing that respects the orig-

inal angle.

The cylinder surface roughness should

be 0.9 micron.

This is essential for a good seating of

the sealing rings, which in turn minimi-

ses oil consumption and guarantees

optimum performance.

For the engine 125

Pistons are oversized due to cylinder

grinding and are subdivided into three

categories: 1st, 2nd and 3rd equal to

0.2-0.4-0.6 mm oversize. These are al-

so classified into 4 categories: A, B-B,

C-C, D-D.

Inspecting the piston rings

- Alternately fit the 3 sealing rings in the cylinder in the area where it keeps its original diameter. Using

the piston, fit the rings perpendicularly to the cylinder axis.

- Measure the opening of the sealing rings using a thickness gauge (see picture).

- Replace the piston rings if values higher than those prescribed are measured.NOTEBEFORE REPLACING ONLY THE PISTON RINGS, MAKE SURE THAT COUPLING CLEARANCEBETWEEN THE PISTON RINGS AND ITS GROOVES, AND THAT BETWEEN THE PISTON AND

Engine

ENG - 148

THE CYLINDER ARE AS SPECIFIED. IN ANY CASE, NEW PISTON SEALING RINGS USED INCOMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THANTHE STANDARD ONES.

Removing the piston- Install piston and pin onto the connecting rod, with the piston arrow aligned facing the exhaust.

- Fit the pin snap ring on the appropriate tool.

- With the opening in the position indicated on the tool

S = left

D = right

- Set the snap ring into its position with the punch.

- Fit the pin stop ring using the plug as shown in the figure.CAUTIONUSING A HAMMER MAY DAMAGE THE RINGS HOUSINGS.NOTETHE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.Specific tooling020430Y Tool for fitting the pin snap rings020454Y Tool to fit pin snap rings (200 - 250)

Engine

ENG - 149

Choosing the gasket

- First fit the piston into the cylinder, without any

base gasket.

- Fit a comparator on the specific tool

Support to check piston 020428 position

- Set to zero the comparator by positioning the tool

on an abutment plane. Keeping the zero position,

fit the tool on the cylinder and lock it with the 2 nuts

supplied as shown in the figure.

- Rotate the crankshaft up to TDC (the reversal

point of the dial gauge rotation).

- Place the comparator on the piston as shown in

figure and detect the piston protrusion.

- By means of the chart below, identify the thick-

ness of the cylinder base gasket to be used upon

refitting. By correctly identifying the cylinder base

gasket thickness, an adequate compression ratio

can be maintained

- Remove the specific tool and the cylinder.NOTEMEASURE PROTRUSION ON 125 ENGINES, AND RECESSON 200 ENGINES.

Engine

ENG - 150

Refitting the piston rings

- Place the oil scraper spring on the piston.

- Fit the oil scraper ring keeping the gap opposed

to the spring union and the word "top" facing the

piston crown. In any case, the chamfered side of

the must be facing the piston crown.

- Fit the middle piston ring with the identification

letter or the word "top" facing the piston crown. In

any case, the tapered side of the ring must be fac-

ing opposite the piston crown.

- Fit the top piston ring with the word "top" or the

reference mark facing the piston crown.

- Offset the piston ring gaps on the three rings by

120º as shown in the figure.

- Lubricate the components with engine oil.

- 200 engines use the top ring with an L-shaped

section.NOTETHE 2 PISTON RINGS ARE MADE WITH A TAPERED CY-LINDRICAL CONTACT SECTION. THIS IS TO OBTAIN ABETTER BEDDING.

Refitting the cylinder

- Fit the cylinder base gasket of the chosen thickness.

- Using the fork support and the retaining clamp, fit the cylinder as shown in the figure.NOTE

BEFORE FITTING THE CYLINDER, CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT ANDLUBRICATE THE CYLINDER LINER.

Specific tooling

020393Y Piston fitting ring

020287Y Band for fitting the piston on the cylinder

Engine

ENG - 151

Inspecting the cylinder head

- Using a trued bar and a thickness gauge, check

that the cylinder head surface is not worn or dis-

torted.

Maximum run-out allowed: 0.05 mm

- Check that the camshaft and the rocker pin bear-

ings show no signs of wear.

- Check that the cylinder head cover surface, the

intake manifold and exhaust manifold are not

worn.

Characteristicbearing «A»

Ø 12.000 ÷ 12.018

bearing «B»

Ø 20.000 ÷ 20.021

bearing «C»

Ø 37.000 ÷ 37.025

Engine

ENG - 152

Inspecting the timing system components

- Check that the guide slider and the tensioner pad

are not excessively worn.

- Check that the chain assembly, the camshaft

driving pulley 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.

- Remove the central screw with the washer and

the tensioner spring. -Check that the one-way

mechanism is not worn.

- Check the condition of the tensioner spring.

- If signs of wear are found, replace the whole as-

sembly.

Inspecting the valve sealings

- Fit the valves into the cylinder head.

- Alternatively test the intake and outlet valves.

- The test should be carried out by filling the manifold with fuel and checking that the head does not

ooze through the valves when they are just pressed by the fingers.

Engine

ENG - 153

Inspecting the valve housings- Check the width of the mark on the seat of valve

«V». Max. wear: 1.6 mm.

- Remove any carbon deposits from the valve

guides.

- Measure the inside diameter of each valve guide.

- Measure according to the rocker thrust direction

at three different heights.

- If the width of the mark on the valve seat or the

diameter of the valve guide exceed the specified

limits, replace the cylinder head.

CharacteristicValve seat wear: Intake guide

admissible limit: 5.022

Valve seat wear: Intake guide

Standard diameter: 5.000 ÷ 5.012 mm

Valve seat wear: Outlet guide

Admissible limit: 5.022

Valve seat wear: Outlet guide

Standard diameter: 5.000 ÷ 5.012 mm

Inspecting the valves- Measure the width of the sealing surface on the valve seats and on the valves themselves.

Engine

ENG - 154

Sealing surface width: After use: Intake and outlet: 1.6 mm

- If the sealing surface on the valve is wider than the specified limit, damaged in one or more points or

curved, replace the valve with a new one.CAUTIONDO NOT CHANGE THE VALVE FITTING POSITION (RH - LH).

CharacteristicValve wear check: Standard: intake and outlet:

0.99 ÷ 1.27 mm

- Measure the diameter of the valve stem at the three positions indicated in the diagram.

- Calculate the clearance between the valve and its guide.

- Check that there are no signs of wear on the faying surface with the set screw articulated terminal.

- If no anomalies are found during the above checks, the same valves can be reused. For better sealing

results, it is advisable to grind the valves. Grind the valves gently with fine-grained lapping compound.

Upon grinding, keep the cylinder head in horizontal position. This will prevent the lapping compound

residues from penetrating between the valve stem and the guide (see figure).CAUTION

TO AVOID SCORING THE FAYING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPINGCOMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH ASUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.NOTE

DO NOT CHANGE THE VALVE FITTING POSITION

CharacteristicValve check: standard length

Outlet: 94.4 mm

Valve check: standard length

Inlet: 94.6 mm

Valve check: maximum clearance allowed:

Outlet: 0.072 mm

Valve check: maximum clearance allowed

Inlet: 0.062 mm

Valve check: standard clearance:

Outlet: 0.025 ÷ 0.052 mm

Valve check: standard clearance:

Inlet: 0.013 ÷ 0.040 mm

Valve check: Minimum diameter allowed:

Engine

ENG - 155

Outlet: 4.95 mm

Valve check: Minimum diameter allowed:

Inlet: 4.96 mm

Valve check: Standard diameter:

Inlet: 4.972 ÷ 4.987 mm

Valve check: Standard diameter:

Outlet: 4.96 ÷ 4.975 mm

Engine

ENG - 156

Inspecting the springs and half-cones

- Check that the spring upper caps and the cotters show no signs of abnormal wear.

Refitting the valves

- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.

- Using the specified punch, fit the 4 sealing rings.

- Fit the valves, the springs and the plates. Using the specified tool with the appropriate adaptor, com-

press the springs and insert the cotters in their seats.NOTE

DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-ERENCE COLOUR ON THE COTTERS SIDE (TURNS WITH GREATER PITCH).

Specific tooling


020382Y Tool for removing valve cotters fitted with part 012


Engine

ENG - 157

Inspecting the cam shaft

- Check the camshaft bearings for signs of abnormal wear.

- Check the cam height.

- Check there is no wear on the camshaft groove and related retention plate.

- If values measured are not within the specified limits or there are signs of excessive wear, replace the

defective components with new ones.

- 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 the automatic valve-lifter return spring is not deformed by over-stretching.

- Replace any defective or worn component.

- Check there are no signs of wear or scoring on the rocker pins.

- Check the internal diameter of each rocker arm.

- Check there are no signs of wear on the contact pads with the cam and on the jointed adjustment

plate.

Characteristic

Engine

ENG - 158

Rocking levers inside diameter: Standard diameter

Ø 12.000 ÷ 12.011 mm

Rocking lever pins diameter: Standard diameter

Ø 11.977 ÷ 11.985 mm

Camshaft check: Maximum axial clearance admitted:

0.42 mm

Camshaft check: Standard axial clearance:

0.11 ÷ 0.41 mm

Camshaft check: Standard height

Outlet: 29.209 mm

Camshaft check: Standard height

Inlet: 30.285 mm

Camshaft check: Minimum diameter admitted

Bearing B Ø: 19.950 mm

Camshaft check: Minimum diameter admitted

Bearing A Ø: 36.94 mm

Camshaft check: Standard diameter

Bearing B Ø: 19.959 ÷ 19.98 mm

Camshaft check: Standard diameter

Bearing A Ø: 36.95 ÷ 36.975 mm

Engine

ENG - 159

Refitting the head and timing system components

- Fit the timing chain sprocket wheel on the crank-

shaft, with the chamfer facing the insertion side.

- Loop the timing chain around the sprocket on the

crankshaft.

- Fit the chain tensioner pad from the cylinder head

side.

- Fit the spacer and the fixing screw.

- Tighten the screw to the prescribed torque.

- Fit the pins and rocker levers.

- 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 opposed to the

rocking levers.

- Insert the retention plate and tighten the two

screws shown in the picture to the prescribed tor-

que.

Engine

ENG - 160

- Refit the spacer on the camshaft.

- Rotate the engine so that the piston is at top dead

centre, using the reference marks on the flywheel

and the crankcase.

- In this position, fit the chain onto the camshaft

control pulley.

- Insert the pulley on the camshaft while keeping

the reference 4V matching the reference mark on

the head.

- Fit the counterweight and tighten the fixing screw

to the prescribed torque..

- Fit the end-stop ring on the automatic valve-lifter

assembly and fit the automatic valve-lifter cam to

the camshaft.

- Fit the automatic valve-lifter return spring.

During this operation the spring must be loaded

approximately 180°.

- Fit the automatic valve-lifter retaining dish, using

the counterweight fixing screw as reference.

- Tighten the central fixing screw to the prescribed

torque.

- Set the tensioner slider to its home position.

- Fit the chain tensioner on the cylinder using a

new gasket, and tighten the 2 screws to the pre-

scribed torque.

- Insert the chain tensioning spring, together with

the central screw and washer, and tighten the cap

to the prescribed torque.

- Adjust valve clearance

- Fit the spark plug.

Electrode gap: 0.8 mmNOTEGREASE THE END-STOP RING TO PREVENT IT COMINGOUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)Timing chain tensioner support screw 11 ÷ 13Spark plug 12 ÷ 14 Starter ground screw 7 ÷ 8.5Timing chain tensioner pad screw 10 ÷ 14 Starterground bell screw 11 ÷ 15 Timing chain tension-er central screw 5 ÷ 6 Camshaft retention platescrew 4 ÷ 6

Engine

ENG - 161

- Fit the timing chain guide pad.

- Insert the centring dowels between the cylinder head and the cylinder, fit the cylinder head gasket and

the cylinder head.

- Lubricate the stud bolt threading.

- Tighten up the nuts to a pre-torque of 7±1 Nm

- Carry out an angle rotation of 180° (2 rotations of 90°each)

- To carry out the operations described above, follow the tightening sequence indicated in the figure.

- Fit the two screws on the timing chain side and tighten them to the prescribed torque.NOTE

BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEANUSING A JET OF COMPRESSED AIR.

Locking torques (N*m)Timing chain tensioner support screw 11 ÷ 13

Engine

ENG - 162

Engine

ENG - 163

Refitting the intake manifold

- Assemble the inlet manifold and tighten the 3

screws.NOTEFOR THE SPECIAL SCREWS OF THE 125 CC VERSION,USE COMMERCIAL INSERTS AND INSERT HOLDERS.

Crankcase - crankshaft

Splitting the crankcase halvesengine crankcase opening

ble>

- First remove the following

units:

transmission cover, driving

pulley, driven pulley and belt,

rear hub cover, gears, bear-

ings and oil seals as descri-

bed in the transmission

chapter.

Remove the oil sump, the by-

pass, the chain compartment

cover and the oil pump as de-

scribed in the lubrication

chapter.

- Remove the flywheel cover with the water pump, the fly-

wheel, the stator as described in the magneto flywheel

chapter.

- Remove the oil filter and the oil pressure switch.

- Remove the cylinder-piston-head unit as described in the

timing system cylinder head chapter.

- Remove the 2 retainers indicated in the figure and the starter

motor.

Engine

ENG - 164

- Before opening the crank-

case, it is advisable to check

the axial clearance of the

crankshaft. To do this, use a

plate and a support with a

specific tool dial gauge.

- Higher clearances are signs

of wear on the supporting sur-

faces of the crankshaft on the

crankcase.

- Remove the 11 crankshaft

coupling screws.

- Separate the crankcase

while keeping the crankshaft

in one of the two crankcase

half.

- Remove the crankshaft.

- Remove the crankshaft

halves coupling gasket.

- Remove the two screws and

the internal cover shown in

the figure.

- Remove the flywheel side oil

seal.

- Remove the oil filter fitting


- Check the connecting rod

axial clearance.

- Check the connecting rod

radial clearance.

- Check that the surfaces that

limit the axial clearance are

not scored and with the aid of

a gauge measure the crank-

shaft width as shown in the

figure.

Shimming (only 200 cc)

Engine

ENG - 165

- Check shim washer thick-

ness.

- Check that shim washers

are not scored.

- If the crankshaft-crankcase axial clearance exceeds what

specified and the crankshaft does not show any defect, the

problem must be due to either excessive wear or wrong ma-

chining on the crankcase.

- Check the diameters of both

crankshaft bearings accord-

ing to the axes and surfaces

shown in the figure. Half-

shafts are classified in two

categories, Cat 1 and Cat 2,

as shown in the chart below.

CAUTIONTHE CRANKSHAFT CAN BE REUSED WHEN ITS WIDTH ISWITHIN THE STANDARD VALUES AND SURFACES SHOWNO SIGNS OF SCORING.CAUTIONWHEN OPENING THE CRANKCASES AND REMOVINGTHE CRANKSHAFT, CHECK THAT THE THREADEDSHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-INGS. FAILURE TO OBSERVE THIS PRECAUTION CANDAMAGE THE MAIN BUSHINGS.CAUTIONWHEN SEPARATING THE CRANKCASE KEEP THECRANKSHAFT IN ONE OF THE CRANKCASE HALF. THECRANKSHAFT MIGHT ACCIDENTALLY FALL IF THISRULE IS NOT OBSERVED.NOTEIN CASE OF REUSE, KEEP THE ORIGINAL FITTING POSI-TION.NOTEWHEN MEASURING THE CRANKSHAFT WIDTH, MAKESURE THAT THE MEASUREMENTS ARE NOT MODIFIEDBY THE COUPLING SPOKES WITH THE CRANKSHAFTBEARINGS.NOTEThe 200 cc version crankshaft is fitted with two steel shimwashers. Take note of the fitting position.

Specific tooling

020262Y Crankcase splitting strip

CharacteristicCamshaft bearings: Standard diameter: Cat. 2

29.000 ÷ 29.006

Camshaft bearings: Standard diameter: Cat. 1

Engine

ENG - 166

28.994 ÷ 29.000

Engine crankcase opening: Standard thick-ness

2.175 ÷ 2.225 mm

Crankshaft width with shim washers: standardsizes

51.40 ÷ 51.45 mm

Engine crankcase opening: standard sizes

55.75 ÷ 55.90 mm (125)

Crankshaft - connecting rod radial clearance:Standard clearance

0.036 ÷ 0.054 mm

Crankshaft - connecting rod axial clearance:Standard clearance

0.20 ÷ 0.50 mm

Crankshaft - crankcase axial clearance: Stand-ard clearance

0.15 ÷ 0.40 mm (when cold)

Inspecting the crankshaft alignment

- Install the crankshaft on the support and measure

the misalignment at the 4 points indicated in figure.

- Check that the crankshaft cone, the tab fitting, the

oil seal flow, the knurling and the threaded tabs are

in good working order.

- In case of failure, replace the crankshaft.

The rod head bushings cannot be replaced. There-

fore, the connecting cannot be replaced either

and, when cleaning the crankshaft, be very careful

that no impurities get in through the shaft lubrica-

tion 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.NOTECRANKCASE BEARINGS ARE NOT GRINDABLE .

Engine

ENG - 167

Specific tooling

020074Y Support base for checking crankshaftalignment

CharacteristicMaximum off-line allowed:

A = 0.15 mmB = 0.01 mmC = 0.01 mmD = 0.10 mm

CRANKSHAFT ALIGNMENT

Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo ImmagineCrankshaft alignment

Measure the flows on both X-Y axles

STANDARD DIAMETER (125 - 200 CC)Name Description Dimensions Initials QuantityCat. 1 28.998 ÷ 29.004Cat. 2 29.004 ÷ 29.010

Maximum off-line allowed:

A = 0.15 mm

B = 0.01 mm

C = 0.01 mm

D = 0.10 mm

Specific tooling020335Y Dial gauge magnetic support

Engine

ENG - 168

020074Y Support base for checking crankshaft alignment

Inspecting the crankcase halves

- Before checking the crankcase halves, thoroughly clean all the surfaces and oil pipes.

- For the crankcase half on the transmission side, take particular care when cleaning the housing and

oil pipes of the oil pump, the duct and the by-pass valve, the main bushings and the cooling nozzle on

the transmission side (see figure).

As already described in the lubrication chapter, it is especially important that the by-pass valve housing

shows no wear that may impair the proper sealing of the lubrication pressure adjustment piston.

- For 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.

- Check the coupling surfaces for scratches or deformation, paying special attention to the cylinder/

crankcase surfaces and the crankcase halves coupling surfaces.

- Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in

oil pressure and thus affect the lubricating pressure for the main bushings and the connecting rod.

- Check that the surfaces limiting the crankshaft axial clearance show no signs of wear. To measure

and check sizes follow the procedure described previously for checking crankshaft axial clearance and

dimensions.NOTETHE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENTIMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TODETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKAGE CAN CONSIDERABLYCAUSE A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CONNECTINGROD.NOTETHE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET: THIS GIVES A "LOWPRESSURE" HEAD LUBRICATION; THIS CHOICE HAS BEEN MADE TO REDUCE OIL TEMPER-ATURE. JET CLOGGING IMPAIRS HEAD LUBRICATION AND THE TIMING MECHANISMS. A JETFAILURE CAUSES A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CON-NECTING ROD.

Engine

ENG - 169

Inspecting the crankshaft plain bearings

Refitting the crankcase halves

- Fit the internal bulkhead by locking the 2 screws

to the prescribed torque.

- Fit the oil filter fitting and tighten it to the prescri-

bed torque.

- Place a new gasket on one of the crankcase half,

preferably on the transmission side, together with

the centring dowels.

- Lubricate the main bushings and insert the crank-

shaft in the transmission side crankcase half.

- Couple the 2 crankcase halves.

For the 200 version, reposition shim washers as in

the original fitting.

- Fit the 11 screws and tighten them to the pre-

scribed torque.

- Lubricate the flywheel side oil seal.

- Use the appropriate tool to assemble the oil seal.

- Fit and lubricate a new O-ring on the pre-filter.

Engine

ENG - 170

- Insert the pre-filter and its cover on the engine.

Tighten to the specified torque.NOTEFAILURE TO USE THE SPECIFIC TOOL MAY RESULT INAN INCORRECT DEPTH POSITION AND, AS A CONSE-QUENCE, IN INADEQUATE OIL SEALING.

Specific tooling

020425Y Punch for flywheel side oil seal

Locking torques (N*m)Screws for engine crankcase internal bulk-head (transmission-side half shaft) 4 ÷ 6 Oil fil-ter fitting on crankcase 27 ÷ 33 Engine crank-case coupling screws 11 ÷ 13 engine oildrainage plug/mesh filter 24 ÷ 30

Lubrication

Conceptual diagrams

LUBRICATION CIRCUIT

Engine

ENG - 171

Engine

ENG - 172

Oil pressure check

- After removing the flywheel covers as described in the "Flywheel" chapter, disconnect the electrical

connection of the minimum oil pressure switch and 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 specific tools on the engine once the measurement is complete. Refit the oil pressure

switch and washer, tightening it to the prescribed torque, and fit the flywheel cover.

- If oil pressure reading are not within the specified limits, check in the following order: the oil filter, the

oil by-pass valve, the oil pump and the crankshaft seals.NOTE

THIS CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OILFILTER IN GOOD CONDITION.

Specific tooling

020193Y Gauge for oil pressure check

020434Y Fitting for oil pressure check

020331Y Digital multimeter

Engine

ENG - 173

Oil pump

- Check there are no signs of wear on the oil pump shaft or body.

- Check there are no signs of wear or scoring on the oil pump cover.

- If non-conforming values or signs of wear are found, replace the faulty parts or the assembly.

- Fit the pump cover so positioned that the holes for the crankcase fixing screws are aligned.

- Make sure the gasket is the correct position and refit the pump on the engine crankcase. The pump

can only be fitted in one position. Tighten the screws to the prescribed torque.

- Fit a new O-ring on the pinion.

- Assemble the chain.

- Fit the central screw and the belleville washer. Tighten to the specified torque.

- Assemble the oil pump cover by tightening the two screws to the prescribed torque.NOTE

FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURETHAT THE PUMP TURNS FREELY.

Locking torques (N*m)Screws fixing oil pump to crankcase 5 ÷ 6 oil pump driving crown gear screw 10 ÷ 14 Oil pumpcover screws 0.7 ÷ 0.9

Engine

ENG - 174

Removal

- Always use a new oil seal when refitting.

-Prepare the new oil seal by lubricating its sealing

lip.

- Preassemble the oil guard with the appropriate

tool, positioning the screws.

- Place the sheath on the crankshaft.

- Insert the tool with the oil seal fitted on the crank-

shaft until it comes into contact with the crankcase.

- Position the oil seal by inserting the bracket which

is part of the appropriate tool.

- Tighten the threaded bar onto the crankshaft up

as far as it will go.

- Use the nut to move the base of the tool until you

can feel the oil seal driving fully into position.

- Remove all of the tool components following the

procedure in reverse order.CAUTIONDO NOT LUBRICATE THE KEYING SURFACE ON THE EN-GINE CRANKCASECAUTIONORIENT THE OIL GUARD BY POSITIONING THE CHAINHOUSING CHANNEL FACING DOWNWARDS. ONCE THEPOSITION IS REACHED, DO NOT RETRACT THE OILGUARD. FAILURE TO COMPLY WITH THIS RULE CANCAUSE A WRONG POSITIONING OF THE OIL GUARDCOUPLING SHEATH.CAUTIONFAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TOTHE WRONG TENSIONING OF THE OIL PUMP DRIVINGCHAIN

Specific tooling

020622Y Transmission-side oil seal punch

Engine

ENG - 175

- Undo the 2 clamping screws in the figure and re-

move the cover of the pump control pulley.

- Block the rotation of the oil pump driving pulley

by inserting a screwdriver through one of its holes.

- Remove the central screw with Belleville washer

indicated in the figure.

- Remove the chain.

- Remove the control sprocket wheel and its O-

ring.

- Remove the oil pump by unscrewing the 2 screws

indicated in the figure.

- Remove the sealing gasket.NOTEIT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-SURE THAT THE INITIAL DIRECTION OF ROTATION ISMAINTAINED.

Inspection- Remove the two screws and the oil pump cover.

- Remove the circlip fixing the inner rotor.

- Remove and wash the rotors thoroughly with petrol and compressed air.

- Reassemble the rotors in the pump body, keeping the 2 reference marks visible. Fit the Seeger ring.

- Measure distance between rotors with a thickness gauge at the position shown in the picture.

Engine

ENG - 176

- Measure the distance between the outer rotor and the pump body (see figure).

- Check the axial clearance of the rotors using a trued bar as shown in the figure.

CharacteristicRotor axial clearance:

Limit value allowed: 0.09 mm

Distance between outer rotor and pump body

limit clearance allowed: 0.20 mm

Distance between rotors

limit clearance allowed: 0.12 mm

Engine

ENG - 177

Removing the oil sump

- Remove the oil filler plug, the transmission cover,

the complete driving pulley assembly with belt and

sprocket wheel, as described in the "Transmis-

sion" chapter.

- Drain the oil from the sump as described above.

- Remove the 7 screws, shown in the figure, and

the 2 brackets fixing the rear brake fluid pipe.

- Remove the spring, the by-pass piston, the gas-

ket and the centring dowels shown in the figure.

Inspecting the by-pass valve

- Check the free length of the spring.

- Check that the plunger is not scored.

- Make sure that it slides freely on the crankcase and that it guarantees a good seal.

- Otherwise, eliminate any impurities or replace defective parts.

CharacteristicBy-pass check: Standard length

54.2 mm

Engine

ENG - 178

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 two centring dowels.

- Refit the sump, taking care to locate the spring in the appropriate piece found in the sump.

- Refit the screws and supporting brackets of the rear brake pipes in the reverse order followed for

removal.

- Tighten the screws to the prescribed torque.

- Refit the driving pulley assembly, the belt, the pinion and the transmission cover as described in the

"Transmissions" chapter.

- When testing the lubrication system, refer to the "Crankcase and Crankshaft" chapter regard-

ing lubrication of the crankshaft and connecting rod.

Locking torques (N*m)Oil sump screws 10 ÷ 14

Engine

ENG - 179

SAS valve

Inspecting the one-way valve

Remove the SAS valve.

- Provisionally assemble the rubber sleeve at the SAS valve outlet to ensure tightness.

- Connect the MITYVAC vacuum pump to the rubber sleeve as shown in the photograph.

- Set the pump to the low-pressure mode (VACUUM).

- Operate the pump slowly.

- Check that the oneway valve allows the air to pass through, causing a slight vibration.

- Switch the pump to the pressure mode (PRESSURE).

- Operate the pump slowly and check if there is a perceptible increase in pressure. A small leak is to

be considered as normal.

If failures are detected, replace the pump.NOTEA MALFUNCTIONING ONEWAY VALVE CAN RESULT IN RUBBER SLEEVE AND FILTER OVER-HEATING.NOTEABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING

Specific tooling020329Y MityVac Vacuum pump

Inspecting the cut-off

Remove the SAS valve.

- Connect the MITYVAC pump in low-pressure mode (VACUUM) to the CUT-OFF valve vacuum intake.

- Apply a vacuum value higher than 0.5 BAR.

- Check that this value is kept at all times.

- If a worn seal is detected, replace it.

Engine

ENG - 180

- With a "T" bypass and flexible rubber hoses make a parallel connection between the rubber sleeve

and the vacuum intake of the CUT-OFF valve.

- Connect the bypass to the MITYVAC pump.

- Set the pump to the low-pressure mode (VACUUM).

- Using a pair of long flat needle-nose pliers, choke the rubber hose close to the valve.

- Operate the pump until vacuum is over 0.5 BAR.

- Release the hose and check how the vacuum reacts. - Under normal operation conditions the vacuum

undergoes a slight fall and then readjusts. This is followed by a slow and continuous loss of pressure

up to approx. 0.4 BAR.Now the valve opens and pressure is suddenly set to zero.

Lack of tightness or the fact that the valve opens at different pressure values should be regarded as

faults.Should this occur, replace it.NOTE

LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS IN EXHAUST NOISE (EXPLOSIONS INTHE MUFFLER).INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT IN CATALYTICCONVERTER MALFUNCTIONNOTE

A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES JEOPARDISING THE CORRECT OPERA-TION OF THE CUT-OFF VALVE, CAN ALSO COMPROMISE THE IDLE CORRECT FUNCTIONING

Specific tooling

020329Y MityVac Vacuum pump

Engine

ENG - 181

Engine

ENG - 182

Fuel supply

- To clean the filtering element proceed as follows: remove the 4 screws fixing the filter cover that are

indicated in the figure; remove the cover and the paper filtering element; clean by blowing compressed

air and then refit.

- Make sure the filtering element is in the correct position.

- Check that the air passage sections are not distorted or broken.

- Check that the filter housing cover coupling is adequately sealed.NOTE

FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RESULT IN WRONG VACUUM INSIDE THEFILTER HOUSING WHICH IN TURN, MAY CAUSE VARIATIONS IN THE CARBURETION.

Removing the carburettor

Remove the fuel tank,

Remove the right inspection cover,Remove the central inspection cover,Disconnect the connector.

Engine

ENG - 183

Remove the clamp and slide off the

heater pipe «1».

Plug the heater pipe «1» so that cool-

ant does not spill out.

Loosen the clamp «2» of the intake manifold sleeve «3».NOTE

THE CARBURETTOR IS NOW CONNECTED TO THE THROTTLE CABLE. OPERATE WITH CAU-TION SO AS NOT TO DAMAGE ANY COMPONENT.

Release the carburettor from the

sleeve «3» and partially remove it.CAUTIONOPERATE WITH CAUTION. DO NOT DAMAGE THE FIXINGTONGUES WHEN REMOVING THEM.

Fully unscrew the nut «4» that locks the

throttle grip cable «5».

Slide off the throttle grip cable «5» from

its seat.

Slide off the throttle grip cable head

«6» form the linkage system catch.

Loosen the clamp and slide off the car-

burettor.

Engine

ENG - 184

Remove the clamp.

Slide off the heater pipe «7».

Completely remove the carburettor.

Kehin

- To detach the carburettor from the engine, it is

necessary to detach the air filter and remove the

throttle control transmission, the automatic starter

connection, the clamps anchoring the carburettor

to the filter housing and to the inlet manifold, the

air delivery pipe to the diaphragm, and the intake

fitting.

- Slide off the carburettor and rotate it so that the

screw with the water joint and the pipes can be

removed.NOTETHIS LAST OPERATION IS NECESSARY SO AS NO TOEMPTY THE COOLING SYSTEM.

- Remove the protection, the bracket and the start-

er by undoing the screw shown in the figure.

Engine

ENG - 185

- Remove the 2 screws and the starter support to-

gether with the gasket.

- Remove the clamp and the cover with the airing

filter of the diaphragm chamber.

- Remove the 4 fixing screws shown in the figure

and the vacuum chamber cover.WARNINGUPON REMOVING THE CARBURETTOR COVER, PAY AT-TENTION NOT TO RELEASE THE SPRING ACCIDENTAL-LY.

Engine

ENG - 186

- Remove the vacuum valve and the diaphragm;

- Unscrew the bayonet joint 1/8 of a turn and re-

move it; take out the spring and the vacuum valve

needle.

- Remove the 4 screws shown in the figure.

- Remove the chamber together with the acceler-

ating pump, its control and gasket.

Engine

ENG - 187

- Remove the sealing gasket.

- Remove the intake and outlet valves of the ac-

celerating pump from the float chamberNOTEBE CAREFUL THAT THE ACCELERATING PUMP VALVESARE MADE UP OF NOZZLES, SPRING AND BALL.NOTEAVOID REMOVING THE PISTON OF THE ACCELERATINGPUMP AND ITS CONTROL.

Adequately support the carburettor and with a pin

and hammer remove the float pin by acting on the

throttle control side.

- Remove the float and the pin.

- Remove the maximum jet

- Remove the maximum jet.

Engine

ENG - 188

- Remove the diffuser.

- Remove the sprayer.NOTEWHEN CLEANING THE CARBURETTOR BODY REMOVETHE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY-ER IS FORCED INTO ITS POSITION, DO NOT ATTEMPT TOREMOVE IT AS THIS WILL ONLY DAMAGE IT.

Engine

ENG - 189

- Remove the minimum jet.

- Remove the minimum flow set screw and the

spring.CAUTIONDO NOT TRY TO REMOVE PARTS EMBEDDED IN THECARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,NEEDLE SEAT, STARTER NOZZLE, TRAP COVER FORPROGRESSIONS AND INLET NOZZLE, MINIMUM ANDMAXIMUM AIR GAUGE, THROTTLE VALVE CONTROLSHAFT.DO NOT REMOVE THROTTLE-TO-SHAFT CON-NECTING SCREWS. THE FIXING SCREWS ARE CAULKEDAFTER BEING FITTED AND REMOVING THEM DAMAGESTHE SHAFT.

Adjusting the idle

The engine does not require frequent idle speed

adjustments, but it is essential to strictly follow cer-

tain rules when adjusting idle speed.

Before adjusting the carburettor, make sure that

the lubrication requirements and valve clearance

are met, timing is respected, the spark plug is in

optimum conditions, the air filter is clean and

sealed, and the exhaust system is perfectly

sealed.

Warm up the engine, letting it run at 50

km/h for at least 5 minutes.

Connect the multimeter thermometer

(020331y) to the sump, using a cap

with oil expressly prepared for probes.

Engine

ENG - 190

Start the engine and before adjusting

idle speed, make sure that the oil tem-

perature is between 70 ÷ 80 °C

Using the analyser rpm indicator or any

other instrument (020332y), adjust the

idle screw to obtain 1600 ÷ 1700 rpm.

- The engine does not need frequent idle adjust-

ments, however it is very important to make any

adjustments fully respecting some standards.

- Before adjusting the carburettor make sure to re-

spect the lubrication requirements, valve clear-

ance, and complying timing, spark plug should be

in optimum conditions, air filter clean and sealed,

and the exhaust system tight.

- Warm up the engine by running it at least 5 mi-

nutes at approximately 50 kph.

- Connect the vehicle to the exhaust fumes analy-

ser inserting the probe into a sealed extension pipe

placed at the muffler exit end.

- Connect a millimetre thermometer (020331y) on

the sump, using a cover with oil expressly pre-

pared for probes.

- Start the motor and before adjusting the idle

speed make sure that the oil temperature is be-

tween 70 ÷ 80°C.

- Using the rpm indicator or any other instrument

(020332y), adjust the idle screw to obtain 1600

rpm ÷ 1700 rpm

- 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.

Engine

ENG - 191

- When the oil temperature, the numbers of revs

and the percentage of carbon monoxide are re-

spected the idle carburetion is considered correct.

From the analyser we can draw further informa-

tion:

- carbon dioxide percentages (CO2), the percent-

age of carbon dioxide has an inverted course com-

pared to the percentage of(CO), values over

12.5% are considered correct. Non complying val-

ues indicate lack of tightness in the exhaust sys-

tem.

- 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 val-

ues 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 adjustmentsNOTETHE WASTED SPARK IGNITION SYSTEM OFFERS RE-MARKABLE POWER. READINGS MAY NOT BE ACCU-RATE IF INADEQUATE RPM INDICATORS ARE USED.CORRECT COUPLING OF THE RPM INDICATOR WILL BEINDICATED WHEN IT CAN ALSO READ RPM OVER 6000 ÷8000

Engine

ENG - 192

INDEX OF TOPICS

SUSPENSIONS SUSP

Front

Removing the front wheel

KEY:

1. Grey front wheel rim;

2. Bearing;

3. Spacer;

4. Front wheel left spacer;

5. Front wheel right spacer;

6. Front wheel pin;

7. Tubeless valve;

8. Front brake disc;

9. TE flanged screw;

10. Front cover;

11. Oil seal;

12. Cap.

Suspensions

SUSP - 194

Rest the scooter on its centre stand.

Place a support under the chassis.

Remove the brake calliper.

Loosen the pin locking screw.CAUTIONUPON REMOVING/REFITTING, PAY ATTENTION NOT TODAMAGE THE BRAKE HOSES, DISCS AND PADS.

Unscrew and remove the wheel pin.

Collect the spacers from the wheel left

and right sides.

Remove the wheel.CAUTION

DO NOT ACTUATE ON THE FRONT BRAKE LEVER AFTER REMOVING THE WHEEL, OTHER-WISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT, RESULTING IN BRAKE FLUIDLEAKAGE.

To refit, carry out removal operations but in reverse order.

Front wheel hub overhaul

Remove the front wheel.

Clean the two sides of the hub with a

cloth.

Remove the right oil seal «1».

Remove the right bearing «2» with a

suitable extractor.

Remove the left oil seal «3».

Remove the left bearing «4» with a

suitable extractor.

Carry out a thorough check of the bear-

ings.

Collect the internal spacer «5».

Clean the inside of the hub thoroughly.

Suspensions

SUSP - 195

Wash all the parts with clean deter-

gent.CAUTIONUPON REFITTING, USE A BUFFER WITH A DIAMETEREQUAL TO THE EXTERNAL RING OF THE BEARINGS TOINSERT THE BEARINGS. DO NOT HIT THE BALLS AND/ORTHE INTERNAL RING. MAKE SURE THE FOLLOWINGCOMPONENTS ARE FITTED PERFECTLY IN:

THE LEFT BEARING «4» ON THE HUB;THE SPACER «5» ON THE LEFT BEARING«4»;THE RIGHT BEARING «2» ON THE SPACER«5»;

BEARINGS

Manually rotate the internal ring «1» which must

turn smoothly, without obstacles and/or noise.

There must be no axial clearance. The bearings

presenting these problems must be replaced.CAUTIONCHECK THAT ALL THE PARTS ARE IN GOOD CONDI-TIONS, SPECIALLY THE ONES BELOW.

GASKETS

Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive

wear.

WHEEL PIN

Using a dial gauge, check the wheel pin « 2» ec-

centricity. Replace the pin «2» if the eccentricity

exceeds the limit value.

CharacteristicMaximum eccentricity:

0.25 mm

RIM

Using a dial gauge, check that the radial eccen-

tricity «A» and the axial eccentricity «B» of the rim

«3» do not exceed the limit value.

An excessive eccentricity is usually caused by

worn or damaged bearings.

Replace the rim «3» if, after the bearings are re-

placed, the value is not within the specified limit.

CharacteristicMaximum radial and axial eccentricity:

Suspensions

SUSP - 196

2 mm

Check the tyre conditions.CAUTIONCHECK TYRE TREAD FOR WEAR. BADLY WORN TYRESCOMPROMISE TRACTION AND VEHICLE HANDLING.REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC-TURE BIGGER THAN 5 MM IN THE TREAD. SOME TYRETYPE-APPROVED FOR THIS VEHICLE FEATURE WEARINDICATORS. CHECK THAT THE INFLATION VALVES «1»HAVE THEIR CAPS FITTED IN ORDER TO AVOID UNEX-PECTED FLAT TYRES.BALANCE THE WHEEL AFTER A TYRE IS MENDED.

Handlebar

Removal


Remove the rear handlebar cover.

Undo the three screws indicated and

remove the lower shell.

Undo the indicated screw and remove

electric controls fittings.

Disconnect the connectors of the elec-

tric controls and release the handlebar

from the cable harness.

Suspensions

SUSP - 197

Unscrew the two screws and remove

the u-bolt fixing the brake pump.

Repeat the operations now for the left

brake pump.

Undo the safety screw and handlebar

fixing screw; collect the washer.

Remove the handlebar from the steer-

ing tube.

Remove the throttle grip from the han-

dlebar.


Locking torques (N*m)Locking torque value in Nm

Suspensions

SUSP - 198

Front fork

KEY:

1. Fork base

2. Fork clamp screws

3. Snap ring

4. Rubber cap

5. Sealing cap

6. O-ring

7. Spring

8. Pumping member

9. Counter spring

10. Bottom buffer

11. Left stem

12. Dust guard gasket

13. Safety circlip

14. Sealing gasket

15. Cap

16. Bushing

17. Left wheel holder

18. Sealing washer

19. Lower screw

Suspensions

SUSP - 199

20. Right stem

21. Right wheel holder

22. Locking screw

Removal

STEM REMOVAL


Remove the front mudguard.

Undo and remove the two screws «1».NOTETHE FOLLOWING OPERATIONS REFER TO REMOVINGONLY ONE WHEEL HOLDER STEM - SLEEVE, BUT THEYAPPLY TO BOTH.

Remove the shield back plate.

Remove the upper Seeger ring «2».

Remove the wheel holder stem -

sleeve.

OIL EMPTYING

Place the sleeve in a vice fitted with protection

jaws (aluminium).NOTEGET A COLLECTING CONTAINER BEFORE CARRYINGOUT THESE OPERATIONS.CAUTIONTHE WHEEL HOLDER STEM SLEEVE UNIT CONTAINSOIL. DO NOT TURN IT OVER OR TILT IT TOO MUCH WHENREMOVING IT.

Suspensions

SUSP - 200

Remove the upper closing cap.

Lower the pumping element until the

Seeger ring «1» can be removed.

Remove the Seeger ring «1».

Remove the cap and the O-ring.

Remove the spring and wait some mi-

nutes so that the oil deposited on it

drips off.

Suspensions

SUSP - 201

Drain off the oil into the collecting con-

tainer by pumping it out with the stem.

WHEEL HOLDER STEMS SLEEVES REMOVAL

Drain off the oil.

Place the stem in a vice fitted with pro-

tection jaws (aluminium).

Undo and remove the lower screw «1».

Remove the stem and collect the cen-

tring bushing.NOTEBE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIORWHEN REMOVING THE DIFFERENT COMPONENTS.

Suspensions

SUSP - 202

Remove the pumping member «2» and

the spring «3» from the stem.

Remove the dust guard from the

sleeve.

Remove the Seeger ring.

Remove the oil seal.

Suspensions

SUSP - 203

Remove the washer.

If necessary, remove the spacer «4».

Overhaul

Components check

Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing

them with wet sandpaper (fine grain).

If the scorings are deep, replace the stem.

Use a dial gauge to check that the stem bending is below the limit value.

If over the value, replace the stem.CAUTION

A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BEWEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.

CharacteristicBending limit:

0.2 mm

Suspensions

SUSP - 204

Check that there are no damages and/

or cracks; otherwise, replace it.

If there are signs of excessive wear or

damage, replace the affected compo-

nent.

Replace the following components with new ones:

O-ring gasket on the cap «1»;

oil seal «2»;

dust guard «3»;

Refitting

Place the sleeve in the vice fitted with

protection jaws (aluminium).

Fit the spacer «1».CAUTIONBE EXTREMELY CAREFUL SO THAT NO FOREIGN BOD-IES GET INTO THE SLEEVE OR THE WHEEL HOLDERSTEM.

Insert the washer.NOTESPREAD A THIN LAYER OF FORK OIL ON GASKETS ANDBUSHINGS BEFORE REFITTING THEM.

Suspensions

SUSP - 205

Insert the oil seal.

Fit the Seeger ring.

Fit the dust guard.

Insert the pumping member and the

spring in the stem.

Suspensions

SUSP - 206

Fit the components below on the

sleeve in the following order: the cen-

tring bushing «2» and the stem.

Tighten the lower screw «3».

Refill with oil.

OIL FILLING

Place the wheel holder stem sleeve

unit in a vice fitted with protection jaws

(aluminium).

Fit the spring.

Suspensions

SUSP - 207

Pour fork oil into the wheel holder stem

sleeve unit.CAUTIONNEVER REUSE OIL.

Remove the cap with the O-ring.

Fit the pumping member «1».

Lower the pumping element until the

Seeger ring «2» can be fitted.

Fit the Seeger ring «2».

Suspensions

SUSP - 208

Fit the upper closing cap.

Steering column

KEY:

1. Cap;

2. Lock nut;

3. Adjusting nut;

4. Upper dust guard;

5. Upper bearing;

6. Separating ring;

7. Lower bearing;

8. Lower dust guard.

Suspensions

SUSP - 209

Steering bearing

Check that the ball contact area «1» on the rotating

seat «2» and on the fixed seat «3» is not damaged

or too worn. Replace the whole bearing if neces-

sary.CAUTIONCHECK THAT THE COMPONENTS ARE IN GOOD CONDI-TIONS.CAUTIONAPPLY GREASE ON BALL CONTACT AREAS ON BOTHSEATS «2» AND «3».

Rear

Removing the rear wheel

KEY:

1. Grey rear wheel rim;

2. Rear cover;

3. Internal wheel spacer;

4. External wheel spacer;

5. Nut;

6. Cap;

7. Split pin;

Suspensions

SUSP - 210

8. Brake disc;

*9. TE flanged screw;

10. SPEED SENSOR screw;

11. Tubeless valve.

Park the vehicle on its centre stand.

Remove the exhaust silencer.

Remove the right rare shock absorber.

Slide off the rear brake calliper, keeping it linked to the oil pipe.

Remove the split pin «7» placed on the wheel pin.

Remove the cap «6».

Unscrew and remove the wheel pin nut «5» and the shim washer «4».

Undo and remove the two screws and remove the muffler support plate.

Remove the spacer «3» placed on the wheel pin.

Remove the rear wheel by sliding it off from the right side.CAUTION

UPON REMOVING/REFITTING, PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES, DISCSAND PADS.CAUTION

AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER; OTHERWISE,THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAK-AGE.


Suspensions

SUSP - 211

Swing-arm

KEY:

1. Engine coupling link rod

2. Chassis coupling link rod

3. Silent-block

4. Chassis hinge pin

5. Link rod hinge pin

6. Engine hinge pin

7. Spacer

8. Link rod bushing

9. Resin bushing

10. Nut

11. Washer

12. Washer

13. Self-locking nut

14. Link rod bushing

15. Screw

RemovalWARNING

IT IS NOT NECESSARY TO REMOVE THE SWINGING ARM IN ORDER TO SERVICE IT.

Suspensions

SUSP - 212

- Rest the vehicle on its centre stand.

- Remove the lower cover.

- Remove the footrest.

- Support the engine firmly.

- Unscrew the pin connecting it to the engine and

collect the spacer.

- Operating from both sides of the vehicle, unscrew

the nut from the inside and collect the washer.

- Slide off the pin.

- Once the engine-side swinging arm has been re-

leased, do so with the chassis-side swinging arm,

working from both sides of the vehicle.

- Unscrew the nut and collect the washer.

Suspensions

SUSP - 213

- Slide off the pin connecting it to the chassis.

- Remove swinging arm by sliding it off towards the

front.

OverhaulWARNING

CHECK SWINGING ARM CLEARANCES WITH THE ARM FITTED IN RIDING CONDITIONS.

- Remove the lower cover.

- Remove the footrest.

- Check axial clearance between both swinging

arms using a thickness gauge.

- If values non-conforming with those specified are

measured, remove the arm and replace the Teflon

spacer bushings.

CharacteristicAxial clearance between both swinging arms

Min: 0.6 ; Max: 1.2 mm

Suspensions

SUSP - 214

- Check clearances on the connection between the

chassis-side arm and the chassis using a thick-

ness gauge.

- If values non-conforming with those specified are

measured, remove the arm and replace the Teflon

spacer bushings.

CharacteristicClearance between bushing and plates

Min: 0.6 ; Max: 1.2 mm

- In order to check silent-blocks, unscrew the nut

from inside, undo the screw and remove the silent-

block.

- Check that they are not broken. Otherwise, re-

place them.

- In order to remove the roller casings, remove the Teflon spacer bushing and the internal spacer « A».

- Use a suitable plug to remove the roller casings «B».

- Using a specific tool, drive the new roller casings being careful to position the bearings with the sealing

rings facing outwards.

- Once the ball bearing cages have been fitted, lubricate them with the recommended product.

Specific tooling

020115Y ø 18 punch

020244Y ø 15 punch

Recommended productsAGIP GREASE PV2 Grease for steering bearings, pin seats and swinging arm

White anhydrous-calcium based protective grease for roller bearings; temperature range between -20

C and +120 C NLGI 2; ISO-L-XBCIB2.

Suspensions

SUSP - 215

Refitting

- Follow the removal steps but in reverse order.

- Tighten to the prescribed torque.

LINK RODName Torque in Nm

Connecting rod to chassis retainer 60±20%Connecting rod to engine retainer 40±20%

Chassis connecting rod on engine connecting rod retainer 60±20%Silent-block on chassis retainer 50±20%

Shock absorbers

Removal

Unscrew the upper nut and remove the

screw.

Suspensions

SUSP - 216

Lower the shock absorber.

Unscrew and remove the nut «1».

Slide off the right shock absorber.

Unscrew and remove the nut «2» and

collect the washer.

Remove the screw «3».

Slide off the left shock absorber.


Centre-stand

Remove the two springs indicated.

Undo the indicated screw and slide off

the U-bolt fixing screw.

Suspensions

SUSP - 217


Suspensions

SUSP - 218

INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS

KEY:

1. Front brake lever pipe, front brake calliper

2. Front brake pump /fluid reservoir

3. Front brake control lever

4. Rear brake pump/reservoir

5. Rear brake control lever

6. Rear brake calliper

7. Rear brake pads

8. Rear brake lever pipe, rear brake calliper

9. Front brake calliper

10. Front brake pads

Rear brake calliper

Braking system

BRAK SYS - 220

Removal

Undo the two screws indicated and re-

move the brake calliper.

If you want to replace the calliper, undo

the coupling screw from the pipe to the

calliper.


Locking torques (N*m)Calliper on muffler plate retainer 25±20%

Front brake calliper

Removal


move the brake calliper.

Braking system

BRAK SYS - 221

If you want to replace the calliper, undo

the coupling screw from the pipe to the

calliper.


Locking torques (N*m)Calliper on fork retainer 25±20%

Rear brake disc

Removal

Remove the rear wheel.

Undo and remove the five brake disc

screws.

Remove the brake disc.CAUTIONUPON REFITTING, APPLY THE RECOMMENDED PROD-UCT ON THE THREADING OF THE BRAKE DISC SCREWS.

Recommended productsLOCTITE® 243 Loctite adhesive to assemblycylindrical pieces

Loctite adhesive to assembly cylindrical pieces

Disc Inspection

Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated.

Check the brake disc for wear by measuring the minimum thickness with a micrometer at

different points. Replace the disc if the minimum thickness, even at a single point of the disc,

is less than the minimum value.CAUTION

OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL.

CharacteristicMinimum value for brake disc thickness:

3.6 mm

Braking system

BRAK SYS - 222

Using a dial gauge, check that disc os-

cillation does not exceed the tolerance;

otherwise, replace it.

CharacteristicBrake disc oscillation tolerance:

0.3 mm

Front brake disc

Removal


Undo and remove the five brake disc

screws.

Remove the brake disc.NOTESCREW ALL THE SCREWS MANUALLY AND TIGHTENTHEM OPERATING DIAGONALLYCAUTIONUPON REFITTING, APPLY THE RECOMMENDED PROD-UCT ON THE THREADING OF THE BRAKE DISC SCREWS.

Recommended productsLOCTITE® 243 Loctite adhesive to assemblycylindrical pieces

Loctite adhesive to assembly cylindrical pieces

Disc Inspection

Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated.

Check the brake disc for wear by measuring the minimum thickness with a micrometer at

different points. Replace the disc if the minimum thickness, even at a single point of the disc,

is less than the minimum value.CAUTION

OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL.

CharacteristicMinimum value for brake disc thickness:

3.6 mm

Braking system

BRAK SYS - 223

Using a dial gauge, check that disc os-

cillation does not exceed the tolerance;

otherwise, replace it.

CharacteristicBrake disc oscillation tolerance:

0.3 mm

Front brake pads

Removal

Remove the front brake calliper.

Loosen and slide off both pins.

Slide off the brake pads.

CAUTION

AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER; OTHERWISE,THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAK-AGE.

Braking system

BRAK SYS - 224

Check friction material for appropriate

thickness. If thinner than the minimum

value, replace it.

CharacteristicFriction material minimum thickness

1.5

In case of uneven wear, replace the

brake pads when the friction material

thickness difference is 0.5 mmCAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEYARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

RefittingCAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED.INSIDE THE CALLIPER. UPON REFITTING, DO NOT INVERT THE POSITION OF THE LOCK.

For refitting, follow the operations in reverse order observing the tightening torque.

Rear brake pads

Removal

Remove the Seeger ring.

Braking system

BRAK SYS - 225

Slide off the pin.

Remove the spring.CAUTIONTHE ARROW STAMPED ON THE SPRING MUST ALWAYSBE TURNED IN THE RIDING DIRECTION.

Slide off the brake pads.

Check friction material for appropriate

thickness. If thinner than the minimum

value, replace it.

CharacteristicFriction material minimum thickness

1.5

Braking system

BRAK SYS - 226

In case of uneven wear, replace the

brake pads when the friction material

thickness difference is 0.5 mmCAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEYARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

RefittingCAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED.INSIDE THE CALLIPER. UPON REFITTING, DO NOT INVERT THE POSITION OF THE LOCK.

For refitting, follow the operations in reverse order observing the tightening torque.

Fill - Bleeding the braking system

Rear - combined

REAR BRAKE

Remove the rubber protection cover of

the bleed valve «4».

Insert a transparent plastic pipe in the

bleed valve «4» of the rear brake cal-

liper and insert the other end of this

pipe into a container to collect the fluid.

Quickly press and release the rear

brake lever several times and then

keep it fully pressed.

Loosen the bleed valve 1/4 of a turn so

that the brake fluid flows into the con-

tainer. This will release tension on the

brake lever and will make it go to the

end of stroke.

Repeat the operation until the fluid

draining into the container is air-bubble

free.NOTEWHILE PURGING THE HYDRAULIC SYSTEM, FILL THERESERVOIR WITH THE NECESSARY QUANTITY OF

Braking system

BRAK SYS - 227

BRAKE FLUID. CHECK THAT, DURING THE OPERATION,THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.

Tighten the bleed valve and remove the pipe.

Top-up the reservoir until the correct brake fluid level is obtained.

Refit the rubber protection cover.

Front

Remove the rubber protection cover of

the bleed valve «1».

Insert a transparent plastic pipe in the

bleed valve «1» of the front brake cal-

liper and insert the other end of this

pipe into a container to collect the fluid.

Quickly press and release the brake

lever of the specific brake calliper sev-

eral times, keeping it completely oper-

ated afterwards.

Loosen the bleed valve «1» ¼ of a turn so that the brake fluid flows into the container. This

will release tension on the brake lever and will make it go to the end of stroke.

Repeat the operation until the fluid draining into the container is completely free of air bub-

bles.NOTE

WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARYQUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYSBRAKE FLUID IN THE RESERVOIR.

Tighten the bleed valve «1» and remove the pipe.

Top up restoring the correct front brake fluid level in the reservoir.

Refit the rubber protection cover.

Braking system

BRAK SYS - 228

INDEX OF TOPICS

COOLING SYSTEM COOL SYS

Circuit diagram

KEY:

1. Expansion tank with cap;

2. Radiator / fitting pipe;

3. Radiator fitting / pump pipe;

4. Clamp;

5. Breather pipe;

6. White clic clamps;

7. White clic clamp;

8. Expansion tank cap;

9. Clip;

10. TBEI flanged screw;

11. To the water pump;

12. From the head;

13. Fitting / head sleeve;

14. Fitting;

15. Electric fan connector;

16. Electric fan

Cooling system

COOL SYS - 230

Electric fan check

Key:

1. Battery

2. Main fuses

3. Fan switch

4. Fan

ELECTRIC FAN OPERATION CHECK

To check the electric fan operation:

Remove the legshield.

Disconnect the thermal switch connec-

tor «2» and jump it.

The electric fan should switch on.

Cooling system

COOL SYS - 231

Undo and remove the screw «1» fixing

the radiator.

Locking torques (N*m)M6 fixing screw for radiator (on plastic) 6 (4.44ftlb)

Detach and lift the radiator to release it

from its seat.

Check the connection of connector

«3».

Rotate the fan manually and check that

the blades do not touch the support.

If the rotation is free of obstacles:

Check the battery charge system and

the main fuse.

Thermal switch operation check

Remove the footrest.

Remove the thermal switch «1»

Connect a pocket tester «2» (ohmme-

ter function) to the thermal switch «1»

as shown in the picture.

Immerse the thermal switch in a con-

tainer «3» with coolant.

In the same container, immerse a ther-

mometer «4» ranging from 0° ÷ 150°C

(32° ÷ 302°F).

Place the container on a cooker «5»

and heat the fluid slowly.

Check that the temperature indicated

in the thermometer and the value of the

thermal switch indicated in the tester

correspond to the data stated in the

chart.

Cooling system

COOL SYS - 232

COOLANT TEMPERATURE ºC (ºF) / RESISTANCE VALUES (OHM)Specification Desc./Quantity

below 90º (194º) InfiniteAbove 90º (194º) 0

Coolant replacement

In order to facilitate draining off the cooling system,

follow these steps:

Remove the front central cover.

Undo and remove the expansion tank

cap.

NOTEBEFORE EMPTYING THE COOLING SYSTEM, PREPARE ACOLLECTING CONTAINER OF A MINIMUM CAPACITY OF1.8 LITRES (0.39 GAL).

Loosen the clamp and remove the ra-

diator-pump pipe and allow the coolant

to drain into the collecting container.

Thermostat

Cooling system

COOL SYS - 233

Check

Key:

1.Instrument panel

2.Thermistor

3.Auxiliary fuses

4.Key switch

5.Battery

6.Main fuses

Thermistor operation check

Remove the thermistor «2».

Connect a pocket tester «10» (ohm-

meter function) to the thermistor «2» as


Immerse the thermistor in a container

«11» with oil.

In the same container, immerse a ther-

mometer «12» ranging from 0° + 150°

C (32° + 302°F).

Place the container on a cooker «13»

and heat the fluid slowly.

Cooling system

COOL SYS - 234

Check the temperature indicated in the

thermometer and the value of the ther-

mistor indicated in the tester.

Check that the thermistor varies according to the

temperature as indicated.

OIL TEMPERATURE °C (°F) / RESISTANCE VALUE OHMSpecification Desc./Quantity

50º (122ºF) approximately 226 ± 3485º (185ºF) approximately 64 ± 7

CAUTION

REPLACE THE THERMISTOR IF VALUES DO NOT VARY OR DIFFER WIDELY FROM THE ONESINDICATED ON THE CHART.

Cooling system

COOL SYS - 235

INDEX OF TOPICS

CHASSIS CHAS

Seat

Undo and remove the four screws.

Remove the saddle.

Rear rack

Lift the saddle.


Slide off the screw cover cap.

Undo and remove the screw.


Chassis

CHAS - 237

Driving mirrors

Loosen the nut indicated.CAUTIONTHE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK-WISE.

Rear handlebar cover


Undo the two screws indicated.

Disconnect the connector powering

the instrument panel.

Instrument panel



Disconnect the connector powering

the instrument panel.

Front handlebar cover

Chassis

CHAS - 238


Operating from both sides of the vehi-

cle, undo the two screws indicated.

Operating on both sides of the vehicle,

undo the screw indicated.

Frame central cover

Lift the saddle.

Undo and remove the two screws.

Chassis

CHAS - 239


Remove the central inspection cover

by sliding it off its hooks.

Legshield

Operating on both sides, undo and re-

move the screw.

Remove the front case by sliding it off

its hooks, being careful with the

tongues and related fitting slots.

Chassis

CHAS - 240

Remove the front mudguard.


Operating from both sides, undo and

remove the five screws.CAUTIONPLACE A SUPPORT UNDER THE CHASSIS SO THAT THEFRONT WHEEL DOES NOT TOUCHTHE GROUND.


remove the three screws.


Move the external legshield forwards

and disconnect front headlamp con-

nector.

Chassis

CHAS - 241

Operating from both sides, undo the

two screws and remove the front turn

indicators from the back.

Slide the external front shield off the front fork.

Knee-guard



remove the screw.

Remove the handlebar cover.


Slide off the bag hook.

Chassis

CHAS - 242

Insert the key in the glove-box lock,

turn it clockwise and open the com-

partment.


Close the glove-box.


remove the four side screws.

Disconnect the auxiliary plug socket in

the glove-box.

By making the handlebar rotate, pull

forwards the internal legshield off the

hooks being careful with the fitting

slots.

Footrest

Remove the central inspection cover.

Remove both side fairings.


move the rear screw of the footrest.

Chassis

CHAS - 243


move the two screws of the footrest.

Remove the battery.

Unscrew and remove the bolt inside

the battery compartment.


remove the lower screw fixing it to the

internal legshield.

Remove the footrest being careful with

the tongues and the related fitting slots.

Passenger footrest removal

In riding position, rotate the passenger

footrest «1».

Lift the footrest upper rubber edge «3».

Slide and remove the pin «4».

Remove the passenger footrest «1».NOTETHESE OPERATIONS REFER TO ONLY ONE PASSENGERFOOTREST BUT THEY APPLY TO BOTH.NOTETHIS OPERATION IS NECESSARY ONLY TO REMOVE THEMETAL PART OF THE FOOTREST. TO REMOVE FAIR-INGS, JUST REMOVE THE PASSENGER FOOTREST RUB-BER.

Chassis

CHAS - 244

Side fairings

Left and right fairings removal



Undo the two screws and remove the

passenger footrest rubber.


Push aside the tail section.

Remove the fairing by sliding it off the

hooks, being careful with the tongues

and related fitting slots.

Chassis

CHAS - 245

Air filter

Remove the left side fairing.


Loosen the intake manifold clamp.

Slide off the intake manifold.

Undo the two screws fixing the filter

casing.

Remove the clamp fastening the gas

recovery pipe to the cylinder head cov-

er.

Remove the filter casing.

Tail guard




move the four.

Chassis

CHAS - 246

Undo and remove the two screws in-

side the helmet compartment.


move the screw.


screws.

Chassis

CHAS - 247

Remove the tail section from it fittings

with the side fairings.

Move the tail section backwards and

disconnect the rear light connector.

Undo the two fixing screws and remove

the seat lock.

Remove the tail section by sliding it

backwards.


move the tail section clamp.

Rear mudguard

Undo and remove the three screws.

Chassis

CHAS - 248

Undo the three screws and remove li-

cense plate.


Undo and remove the screws indica-

ted.

Undo the screw and slide off the li-

cense plate light backwards.

Chassis

CHAS - 249

Disconnect the license plate light con-

nector.

Remove the rear mudguard.

Should the rear mudguard holder frame be re-

moved before taking out the rear mudguard pro-

ceed as follows:


Helmet bay

Remove the saddle




Chassis

CHAS - 250

Working on both sides of the vehicle,

undo the screw indicated and collect

the washer.


Front mudguard


remove the two screws.

Slide off the front mudguard forwards.

Fuel tank

Remove the saddle




Disconnect the fuel level sensor power

connector.

Release the tank from the fuel pipes.

Chassis

CHAS - 251


Radiator fan

Drain off the system.Remove the shield back plate.Remove the legshield.Disconnect the electric fan connector.

Disconnect the two thermal switch con-

nectors.

Loosen the clamps and remove the

three pipes.

Chassis

CHAS - 252


Slide off the radiator upwards.

Expansion tank

Drain off the cooling system:


Remove the shield back plate.

Loosen and remove the clamp.

Loosen and remove the clamp.NOTEUPON REFITTING, REPLACE THE REMOVED CLAMPSWITH NEW ONES.

Chassis

CHAS - 253


remove the screw.

Remove the expansion tank.

Lower cover

Undo and remove the rear screw.

Undo and remove the two side screws.


Chassis

CHAS - 254

Undo and remove the screw fixing it to

the legshield on the front wheel hous-

ing.


Lift the footrest and slide the lower

shield off its hooks being careful with

the tongues and related fitting slots.

The lower shield can be split into right and left sec-

tions.

To do this, proceed as follows:


Slide off the lower shield to separate it

into a right and a left section.

Chassis

CHAS - 255

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Carry out the listed checks before delivering the vehicle.WARNING

BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.

Aesthetic inspection

- Paintwork

- Fitting of Plastic Parts

- Scratches

- Dirt

Tightening torques inspection

- Safety locks:

front and rear suspension unit

front and rear brake calliper retainer unit

front and rear wheel unit

engine - chassis retainers

steering assembly

- Plastic parts fixing screws

Electrical system

- Main switch

- Headlamps: high-beam lights, low-beam lights, tail lights (front and rear) and their warning lights

- Headlight adjustment according to regulations in force

- Front and rear stop light switches and their bulbs

- Turn indicators and their warning lights

- Instrument panel lights

- Instrument panel: fuel and temperature indicator (if present)

- Instrument panel warning lights

- Horn

- Electric start-up

- Engine stop via emergency stop switch and side stand

- Saddle electric opening switch (if present)

Pre-delivery

PRE DE - 257

- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if

required, program the control unit/s again: consult the technical service website to know about available

upgrades and details regarding the operation.CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFOREIT IS FIRST USED SHORTENS BATTERY LIFE.CAUTION

UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR AP-PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER ORVEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS ORCIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYEPROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.KEEP OUT OF THE REACH OF CHILDREN.CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USINGA FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSEA FIRE.

Levels check

- Hydraulic braking system fluid level

- Rear hub oil level

- Engine coolant level (if present)

- Engine oil level

- Mixer oil level (if present)

Road test

- Cold start

- Instrument panel operation

- Response to throttle control

- Stability when accelerating and braking

Pre-delivery

PRE DE - 258

- Front and rear brake efficiency

- Front and rear suspension efficiency

- Abnormal noise

Static test

Static check after test drive:

- Restarting when warmed up

- Starter operation (if present)

- Minimum holding (turning the handlebar)

- Uniform turning of the steering

- Possible leaks

- Radiator electric fan operation (if present)

Functional inspection

- Hydraulic braking system

- Brake levers stroke

- Clutch - Check for correct operation

- Engine - Check for correct general operation and absence of abnormal noise

- Other

- Documentation check:

- Chassis and engine numbers check

- Supplied tools check

- License plate fitting

- Locks checking

- Tyre pressure check

- Installation of mirrors and any possible accessories

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

Pre-delivery

PRE DE - 259

Derbi Rambla 125 (en)

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