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DERBI

NACIONAL MOTOR, S.A.U. Derbi

INDEX OF TOPICS

CHARACTERISTICS TOOLING MAINTENANCE ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS BRAKING SYSTEM COOLING CHASSIS PRE-DELIVERY

CHAR TOOL MAIN ELE SYS ENG VE ENG SUSP BRAK SYS COOL SYS CHAS PRE DE

SYSTEM

INDEX OF TOPICS

CHARACTERISTICS

CHAR

Characteristics

Rules Safety rules


GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully.
CAUTION

USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE STARTING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM PARTS. DO NOT HOLD ANY MECHANICAL OR OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOTER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND EVEN 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 CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. FUEL
CAUTION

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

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.


CAUTION

KEEP OUT OF THE REACH OF CHILDREN. HIGH-TEMPERATURE COMPONENTS CHAR - 6

Characteristics

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 OIL
CAUTION

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


CAUTION

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE 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 WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
CAUTION

KEEP OUT OF THE REACH OF CHILDREN. HYDROGEN GAS AND BATTERY ELECTROLYTE
CAUTION

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 PROTECTIVE APPAREL. IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT COOL WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES, CHAR - 7

Characteristics

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIALIST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGARETTES 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 ACTIVATED.

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 BUT IN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY REMOVAL 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 PARTS AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD. DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUT ELECTRICAL 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.

CHAR - 8

Characteristics

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 COMPONENTS
CAUTION

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

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE 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 applying 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 vehicle 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 relevant 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.

CHAR - 9

Characteristics

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 WAY ROUND. 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 TORQUE
CAUTION

DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH. BRAKE FLUID
CAUTION

DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQUIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM. DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT HAVE BEEN OPEN FOR A PROLONGED TIME. SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE TO FAULTS IN THE HYDRAULIC CIRCUIT. MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT SMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND INSPECTION 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 BRAKE
CAUTION

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 TRACES OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT. IF THE SCOOTER IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS, OR IF 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 recommended in the 'Recommended products table' is already mixed and ready to use.

CHAR - 10

Characteristics

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 LEVEL MARKED "MIN".
CAUTION

COOLANT IS TOXIC IF INGESTED; CONTACT WITH YOUR EYES OR SKIN MAY CAUSE IRRITATION. IF THE FLUID GETS IN CONTACT WITH THE EYES OR SKIN, RINSE REPEATEDLY WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE. IF SWALLOWED, INDUCE VOMITING, RINSE MOUTH 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 COOLANT IS UNDER PRESSURE AND VERY HOT. CONTACT WITH SKIN OR CLOTHES MAY CAUSE SEVERE BURNS AND/OR INJURIES. TYRES
CAUTION

CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS. THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS SLIPPERY. 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 FUEL THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER. A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT SIMPLY 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 inside the front glove-box in order to read this number.

CHAR - 11

Characteristics

Engine number The engine number is stamped near the rear shock absorber lower support.
CAUTION ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY.

Dimensions and mass


SIZES
Specification Max. length Max. length (to brake levers (to mirrors)) Max. height (to the rear-view mirrors) Saddle height Wheelbase Minimum ground clearance Kerb weight Desc./Quantity 1965 mm 720 mm (890 mm) 1.143 mm 790 mm 1360 mm 130 mm 148 kg

Engine
ENGINE
Specification Engine model Engine type Valve quantity Cylinder quantity Overall engine capacity Bore/stroke Compression ratio MAX power MAX. torque Start-up Engine revs at idle speed Clutch Lubrication system Cooling Valve clearance Carburettor model (125): Carburettor model (200): Supply Fuel IGNITION Ignition advance (125)
TECHNICAL DATA

Desc./Quantity M281M (125) M282M (200) Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication system, overhead camshaft. 4 1 124 cm (125) 198 cm (200) 57 mm / 48.6 mm (125) 72 mm / 48.6 mm (200) 12.0 0.5 : 1 (125) 11.5 0.5 : 1 (200) 11 kW at 10,000 rpm (125) 14 kW at 8,500 rpm (200) 11.7 Nm at 7,500 rpm (125) 19 Nm at 6,500 rpm (200) Electric 1600 100 rpm Automatic centrifugal dry clutch Wet sump forced lubrication system. forced-circulation air cooling driven by a centrifugal pump Inlet: 0.10 Outlet: 0.15 CVK7 30 Keihin CVK7 30 Keihin WVF7 29 WALBRO Vacuum pump Use premium unleaded petrol only, with minimum octane rating of 95 (NORM) and 85 (NOMM). Capacitive discharge ignition, variable advance Variable ignition advance by microprocessor:

CHAR - 12

Characteristics

Specification

Ignition advance (200)

Spark plug Spark plug electrode gap

Desc./Quantity 10 1 to 2,000 rpm 34 1 from 4,500 to 10,000 rpm Variable (before TDC) from: 10 1 to 2,000 rpm 32 1 to 6,500 rpm NGK CR7EB 0.7 - 0.8 mm

Transmission
TRANSMISSION
Specification Gear Primary drive Secondary Engine/wheel total ratio Minimum ratio for continuos transmission Maximum ratio for continuos transmission Desc./Quantity continuous and automatic variator V-belt With gears 1/6.36 (125) 1/6.54 (200) 36.5 (125) 22.36 (200) 10.95 (125) 7.88 (200)

Capacities
CAPACITY
Specification Fuel (reserve included) Fuel reserve Engine oil - engine oil change and engine oil filter replacement Transmission oil Fork oil Depth of fork oil level from the rim / without spring / fork included Coolant Seats Vehicle max. load (rider + passenger + luggage) Desc./Quantity 9l 1.5 l 1100 cm 250 cm 135 1 cm per stem 99 1.5 mm 1.5 l (50% water + 50% ethylene glycol antifreeze fluid) 2 210 kg

Electrical system
BULBS/WARNING LIGHTS
1 2 3 4 5 6 7 8 9 10 11 12 Specification High-/low-beam bulb Tail light bulb Front turn indicator bulbs Rear turn indicator bulbs Rear tail light /stop light bulb License plate light bulb Instrument panel lighting bulb Turn indicator warning light High-beam warning light Low fuel warning light Engine oil pressure warning light High coolant temperature gauge warning light Desc./Quantity 12 V - 55 W - H7 12V - 5W 12 V - 10 W (Amber) 12 V - 10 W (White) 12 V - 5/21 W (Red) 12V - 5W LED LED LED LED LED LED

ELECTRICAL SYSTEM
Specification Battery Desc./Quantity 12V - 10 Ah

CHAR - 13

Characteristics

Specification (Permanent magnet) Generator

Desc./Quantity 12V - 180W

Frame and suspensions

CHASSIS AND SUSPENSIONS


Specification Size "A" Size "B" Trail Chassis type Steering inclination angle Front suspension Front suspension travel Rear suspension Rear suspension travel Desc./Quantity 423.5 mm 479 mm 86.2 mm High-strength steel tubular chassis, single spar at the front, superimposed double cradle at the rear. 26.5 Hydraulic action telescopic fork 100 mm hydraulic action double-acting shock absorber, adjustable preloading 80 mm

Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity 260-mm disc brake with hydraulic transmission 220-mm disc brake with hydraulic transmission

Wheels and tyres


WHEELS AND TYRES
Specification Wheel rims Front wheel rim Rear wheel rim Tyres Front tyre Rear tyre Rear tyre standard inflation pressure Front tyre standard inflation pressure Front tyre standard inflation pressure with passenger Rear tyre standard inflation pressure with passenger Desc./Quantity Made of light alloy 2.75 x 15" 3.00 x 15" Without inner tube (Tubeless) 120/70 - 15'' 56P 130/80 - 15'' 63P 200 kPa (2.0 bar) 200 kPa (2.0 bar) 200 kPa (2.0 bar) 230 kPa (2.3 bar)

CHAR - 14

Characteristics

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 CHAR - 15

Characteristics

20. Washer 21. Acceleration pump kit

125cc Version Kehin


CARBURETTOR 125 CC
Specification Model Diffuser Engine-side coupling Float Petrol inlet valve needle seat Start-up air inlet hole Start-up jet Minimum jet Idle air screw open in turns Minimum air hole Maximum air hole Maximum jet Throttle valve Sprayer Tapered pin Notch Desc./Quantity CVK7 30 Keihin 29 mm 40 mm 1.2 150 42 35 2 130 70 105 Standard 2.8 mm NDVA

200cc Version Kehin


CARBURETTOR 200 CC
Specification Model Diffuser Engine-side coupling Float Petrol inlet valve needle seat Start-up air inlet hole Start-up jet Minimum jet Idle air screw open in turns Minimum air hole Maximum air hole Maximum jet Throttle valve Sprayer Tapered pin Notch Desc./Quantity CVK7 30 Keihin 29 mm 40 mm 1.2 150 42 38 2 115 70 100 Standard 2.8 mm NDVA

Tightening Torques
HANDLEBAR
Name Handlebar to fork retainer Torque in Nm 4820%

CHAR - 16

Characteristics

Name Safety screw Steering set nut Steering series fixing lock nut Instrument panel support to handlebar retainer Mirror supports to handlebar retainer Mirrors retainer

Torque in Nm 2020% 1520% 11020% 620% 5220% 2520%

CHASSIS
Name License plate holder curved support to chassis retainer Passenger grab handle to chassis retainer Horn to chassis retainer Regulator to chassis retainer Switch to chassis retainer Fuel tank to chassis retainer Helmet compartment to chassis retainer Air deflector to chassis retainer Coil to chassis retainer Torque in Nm 2520% 2520% 1020% 1020% 1020% 1020% 520% 520% 520%

ELECTRICAL SYSTEM
Name Starter motor cable retainer Battery to relay retainer Starter motor on relay retainer Battery cable harness ground lead retainer Torque in Nm 520% 420% 420% 1020%

SADDLE
Name Hinge on saddle retainer Torque in Nm 720%

LOCKS
Name Glove-box lock on cover retainer Saddle lock on right and left half-tail sections retainer Saddle lock on helmet compartment retainer Torque in Nm 420% 320% 520%

INSTRUMENT PANEL
Name Instrument panel to rear panel retainer Instrument panel to instrument panel support retainer Rear panel to handlebar retainer Front panel to lower clamp retainer Front panel to rear panel retainer Lower clamp to rear panel retainer Left and right tool holder retainer Torque in Nm 0.820% 4.520% 120% 120% 320% 120% 520%

REAR BODYWORK
Name Retroreflector to license plate holder retainer License plate to license plate holder retainer Rear taillight to right and left half-tail sections retainer Front retainer for right and left half-tail sections on helmet compartment Rear retainer for right and left half-tail sections on helmet compartment Rear light cover on license plate holder retainer Rear light cover on helmet compartment retainer Rear light cover on tail sections retainer License plate holder on right and left half-tail sections retainer License plate holder on rear mudguard chassis retainer Luggage carrier cover on luggage carrier retainer Torque in Nm 1.520% 120% 120% 420% 120% 120% 6 120% 320% 520% 120%

CHAR - 17

Characteristics

Name Retainer between passenger grab handle cover and passenger grab handle Right and left half-tail sections on helmet compartment retainer Fuel probe lid on helmet compartment retainer Retainer for lower lock of right and left half-tail sections on right and left half-tail sections

Torque in Nm 120% 120% 120% 320%

CENTRAL BODYWORK
Name Central inspection cover on helmet compartment retainer Central inspection cover on right and left fairings retainer Left side inspection cover retainer Right side inspection cover retainer Battery cover retainer Footrest retainer Right and left lower shield retainer Glove-box lid on internal legshield retainer Internal legshield to external legshield retainer Glove-box net on internal legshield retainer Glove-box lid reinforcing retainer Bag hook retainer Air intake on internal legshield retainer Torque in Nm 120% 320 320% 320% 320% 320% 320% 120% 120% 120% 120% 120% 120%

FRONT AND REAR BRAKE


Name Calliper on fork retainer Calliper on muffler plate retainer Pipe cable guide on link rod retainer Pipe cable guide on air deflector retainer Right and left pump on handlebar retainer Rear calliper support to muffler plate retainer Rear calliper support on muffler plate retainer Front pipe cable guide on fork retainer Torque in Nm 2520% 2520% 1020% 520% 1020% 2520% 2520% 1020%

FRONT BODYWORK
Name Right and left air intake on shield retainer Right and left turn indicators on external legshield retainer Front headlamp on external legshield retainer External legshield on cover retainer External legshield on shield retainer Front mudguard clamp on fork retainer External legshield on under-footrest retainer Front mudguard on clamps retainer Case on internal legshield retainer Torque in Nm 120% 120% 120% 120% 120% 120% 320% 520% 220%

FILTER CASING
Name Sleeve on carburettor retainer Sleeve on filter housing retainer Filter housing on engine retainer Torque in Nm 220% 220% 820%

COOLING UNIT
Name Thermal switch retainer Head pipe on radiator retainer Pump pipe on radiator retainer Radiator on bulkhead retainer Electric fan on radiator retainer Expansion tank on air deflector retainer Torque in Nm 2020% 220% 220% 720% 120% 420%

CHAR - 18

Characteristics

FRONT WHEEL
Name Pin retainer Safety screw retainer Torque in Nm 5020% 1020%

LINK ROD
Name Connecting rod to chassis retainer Connecting rod to engine retainer Chassis connecting rod on engine connecting rod retainer Silent-block on chassis retainer Torque in Nm 6020% 4020% 6020% 5020%

EXHAUST
Name Manifold to engine retainer Muffler to manifold retainer Muffler on plate retainer Protection on muffler retainer Torque in Nm 1520% 1620% 2520% 720%

REAR WHEEL
Name Rear wheel retainer Speed sensor screw retainer Speed sensor on muffler plate retainer Torque in Nm 11020% 1020% 1020%

STAND
Name Stand to engine retainer Torque in Nm 2720%

ENGINE
Name Muffler plate on engine Fuel breather pipe cable guide on crankcase Anti-vibration roller Driven pulley shaft nut Clutch assembly nut on driven pulley Driving pulley nut Flywheel nut Oil filter fitting on crankcase Minimum oil pressure sensor engine oil drainage plug/mesh filter oil pump driving crown gear screw Timing chain tensioner support screw Engine crankcase coupling screws Rear hub cover screws Oil pump cover screws Transmission cover screws Oil sump screws Screws fixing oil pump to crankcase Stator unit screws () Starter motor screws Screws for engine crankcase internal bulkhead (transmissionside half shaft) Torque in Nm 2520% 1020% 12 16 54 60 55 60 75 83 54 60 27 33 12 14 24 30 10 14 11 13 11 13 24 27 0.7 0.9 11 13 10 14 56 34 11 13 46

REAR SUSPENSION
Name Right and left shock absorber to chassis retainer Shock absorber on engine bracket retainer Shock absorber on muffler plate retainer Shock absorber bracket on engine retainer Torque in Nm 2520% 4020% 4020% 2520%

CHAR - 19

Characteristics

FUEL SUPPLY SYSTEM


Name Probe to tank retainer Fuel coupling clamp retainer Tank to helmet compartment retainer Petrol pump on helmet compartment retainer Torque in Nm 1.520% 120% 220% 220%

Overhaul data Assembly clearances Cylinder - piston assy.


125 cm Version

COUPLING CATEGORIES
Name Cylinder Cylinder Piston Piston Cylinder 1st Oversize Cylinder 1st Oversize Piston 1st Oversize Piston 1st Oversize Cylinder 2nd Oversize Cylinder 2nd Oversize Piston 2nd Oversize Piston 2nd Oversize Cylinder 3rd Oversize Initials A B C D A1 B1 C1 D1 A2 B2 C2 D2 A3 Cylinder 56.997 57.004 57.004 57.011 57.011 57.018 57.018 57.025 57.197 57.204 57.204 57.211 57.211 57.218 57.218 57.225 57.397 57.404 57.404 57.411 57.411 57.418 57.418 57.425 57.597 57.604 Piston 56.945 56.952 56.952 56.959 56.959 56.966 56.966 56.973 57.145 57.152 57.152 57.159 57.159 57.166 57.166 57.173 57.345 57.352 57.352 57.359 57.359 57.366 57.366 57.373 57.545 57.552 Play on fitting 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059

CHAR - 20

Characteristics

Name Cylinder 3rd Oversize Piston 3rd Oversize Piston 3rd Oversize

Initials B3 C3 D3

Cylinder 57.604 57.611 57.611 57.618 57.618 57.625

Piston 57.552 57.559 57.559 57.566 57.566 57.573

Play on fitting 0.045 - 0.059 0.045 - 0.059 0.045 - 0.059

200 cm Version

COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER)


Name Cylinder/Piston Cylinder/Piston Cylinder/Piston Cylinder/Piston Initials A B C D Cylinder 71.990 71.997 71.997 72.004 72.004 72.011 72.011 72.018 Piston 71.953 71.960 71.960 71.967 71.967 71.974 71.974 71.981 Play on fitting 0.030 - 0.044 0.030 - 0.044 0.030 - 0.044 0.030 - 0.044

COUPLING CATEGORIES (WITH CAST-IRON CYLINDER)


Name Cylinder/Piston Cylinder/Piston Cylinder/Piston Cylinder/Piston Initials M N O P Cylinder 72 72.007 72.007 72.014 72.014 72.021 72.021 72.026 Piston 71.953 71.960 71.960 71.967 71.967 71.974 71.974 71.981 Play on fitting 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054 0.040 - 0.054

Piston rings
125 cm Version

CHAR - 21

Characteristics

ENGINE SEALING RINGS


Name Compression ring Oil scraper ring Oil scraper ring Description Dimensions 57 x 1 57 x 1 57 x 2.5 Initials A A A Quantity 0.15 0.30 0.10 0.30 0.15 0.35

ENGINE SEALING RINGS (1 ST OVERSIZE)


Name Compression ring 1st Oversize Oil scraper ring 1st Oversize Oil scraper ring 1st Oversize Description Dimensions 57.2 x 1 57.2 x 1 57.2 x 2.5 Initials A A A Quantity 0.15 0.30 0.10 0.30 0.15 0.35

ENGINE SEALING RINGS (2 ND OVERSIZE)


Name Compression ring 2nd Oversize Oil scraper ring 2nd Oversize Oil scraper ring 2nd Oversize Description Dimensions 57.4 x 1 57.4 x 1 57.4 x 2.5 Initials A A A Quantity 0.15 0.30 0.10 0.30 0.15 0.35

ENGINE SEALING RINGS (3 RD OVERSIZE)


Name Compression ring 3rd Oversize Oil scraper ring 3rd Oversize Oil scraper ring 3rd Oversize Description Dimensions 57.6 x 1 57.6 x 1 57.6 x 2.5 Initials A A A 0.15 0.35 Quantity 0.15 0.30

200 cm Version

CHAR - 22

Characteristics

ENGINE SEALING RINGS


Name Compression ring Oil scraper ring Oil scraper ring Description Dimensions 72x1.5 72 x 1 72 x 2.5 Initials A A A Quantity 0.15 0.30 0.10 0.40 0.20 0.40

Crankcase - crankshaft - connecting rod


CRANKSHAFT HALF-BEARINGS
Name Crankshaft half-bearings Crankshaft half-bearings Crankshaft half-bearing Description Dimensions Initials B Type - blue C Type - yellow E Type - green Quantity 1.973 1.976 1.976 1.979 1.979 1.982

CRANKCASE - CRANKSHAFT COUPLINGS


Name Crankshaft type 1Crankcase type 1 Crankshaft type 1 Crankcase type 2 Crankshaft type 2 Crankcase type 1 Crankshaft type 2 Crankcase type 2 Description Dimensions Initials E-E C-C C-C B-B Quantity

CRANKSHAFT - CRANKCASE
Name Crankshaft Crankshaft Crankcase Crankcase Description Dimensions Initials Class 1 Class 2 Class 1 Class 2 Quantity 28.998 29.004 29.004 29.010 32.959 32.965 32.953 32.959

CHAR - 23

Characteristics

Fitting clearances Crankshaft/crankcase axial clearance (H): 0.15 0.40 mm (when cold)

CHAR - 24

Characteristics

CRANKSHAFT / CRANKCASE AXIAL CLEARANCE


Name Half shaft, transmission side Half shaft, flywheel side Connecting rod Spacer tool Description Dimensions 16.6 +0-0.05 16.6 +0-0.05 18 -0.10 -0.15 51.4 +0.05 Initials A B C E Quantity D = 0.20 0.50 D = 0.20 0.50 D = 0.20 0.50 D = 0.20 0.50

Slot packing system


125 cm Version

Characteristic
Compression 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 TAKEN WITH NO GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, WITH ITS SUPPORT ON A GROUND SURFACE.

CHAR - 25

Characteristics

METAL HEAD GASKET (0.3)


Name Shimming - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.4 Shimming - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.6 Measure A 1.40 1.65 1.65 1.90 Thickness 0.4 0.05 0.6 0.05

200 cm Version

Characteristic
Compression 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 TAKEN WITH NO GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, WITH ITS SUPPORT ON A GROUND SURFACE.

METAL HEAD GASKET (0.3)


Name Shimming - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.4 Shimming - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.6 Measure A 2.50 2.40 2.40 2.20 Thickness 0.4 0.05 0.6 0.05

CHAR - 26

Characteristics

Name Shimming - Cylinder 67.8 - Head gasket 0.3 - Base gasket 0.8

Measure A 2.20 2.10

Thickness 0.8 0.05

Products
RECOMMENDED PRODUCTS TABLE
Product AGIP RACING 4T, SAE 10W-40 AGIP GEAR SYNTH SAE 75W-90 AGIP FORK 7.5W AGIP FILTER OIL AGIP BRAKE 4 SPECIAL AGIP PERMANENT fluid Description Engine oil Gearbox oil Fork oil Oil for air filter sponge Brake fluid Coolant Specifications 10W-40 API GL4, GL5 FMVSS DOT4+ Biodegradable coolant, ready for use, with "long life" technology and characteristics (pink). Freezing protection up to -40. According to CUNA 956-16 standard. NLGI 2

AGIP GREASE SM2

NEUTRAL GREASE OR PETROLEUM JELLY

Lithium grease with molybdenum for bearings and other points needing lubrication Battery poles

Neutral grease or petroleum jelly.

CHAR - 27

INDEX OF TOPICS

TOOLING

TOOL

Tooling

SPECIFIC TOOLS
Stores code 020622Y Description Transmission-side oil seal punch

020565Y

Flywheel lock calliper spanner

001467Y013

Calliper to extract 15-mm diameter bearings

001467Y035

Bell for OD 47-mm bearings

020150Y

Air heater support

020151Y

Air heater

TOOL - 29

Tooling

Stores code 020193Y

Description 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

TOOL - 30

Tooling

Stores code 020331Y

Description 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

TOOL - 31

Tooling

Stores code 020375Y

Description 28x30 mm punch

020376Y

Adapter handle

020382Y

Tool for removing valve cotters fitted with part 012

020382Y011

adaptor for valve removing tool

020393Y

Piston fitting ring

020412Y

Clutch oil seal punch D 15 mm

TOOL - 32

Tooling

Stores code 020423Y

Description 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

TOOL - 33

Tooling

Stores code 020444Y009

Description 46 x 55 wrench

020444Y010

adaptor ring

020442Y

Pulley lock wrench

020444Y

Tool for fitting/removing the clutch on the driven pulley

020455Y

10-mm guide for oil seal on water pump shaft

020456Y

24 mm adaptor

TOOL - 34

Tooling

Stores code 020454Y

Description Tool to fit pin snap rings (200 - 250)

020477Y

37-mm Adaptor

020483Y

30 mm guide

020489Y

Stud bolt set for hub cover support

TOOL - 35

INDEX OF TOPICS

MAINTENANCE

MAIN

Maintenance

Maintenance chart
ROUTINE
MAINTENANCE TABLE

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: 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 Driven pulley roller casing Safety locks Spark plug driving belt Throttle control Brake disc Air filter SAS filter Engine oil filter Valve clearance Electrical system and battery Braking systems Light circuit Brake control levers Brake fluid ** Coolant level** Exhaust muffler/ silencer Engine oil* Hub oil Headlight aiming adjustment Brake pads Sliding blocks / Variable speed rollers Vehicle test drive Radiator Idle speed Wheels/tyres Suspensions Steering Transmissions Fuel pipes *** 1 I I I A I I C R A I I I I I R I I I I 6 12 L I R R A I C C R I I I L I I I R I A I R I A I I I L I 18 24 L I R R A I C C R I I I L I I I R R A I R I A I I I L I 30 36 L I R R A I C C R A I I I L I I I R I A I R I C A I I I L I 42 48 L I R R A I C C R I I I L I I I R R A I R I A I I I L I 54 60 L I R R A I C C R I I I L I I I R I A I R I A I I I L I

I I I C R A I I I I I R I I I I C I

I I I C R I I I I I R I I I I

I I I C R I I I I I R I I I I

I I I C R A I I I I I R I I I I C I

R I I I L I I R R I I A I I

Spark plug
CAUTION

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.

MAIN - 37

Maintenance

Disconnect the tube. Unscrew the spark plug.

Characteristic
Spark 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.
CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST 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. MAIN - 38

Maintenance

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 RECOMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE

Replacement
Park the vehicle on firm and level ground. Rest the vehicle on its centre stand. Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down.
CAUTION

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. Unscrew and pull out the measuring cap-dipstick.

Place a +300 cm (18.3 cu.in) capacity container under the drain screw. Unscrew 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 capdipstick. Start the engine and let it run for several minutes. Stop the engine and let it cool down. Check the transmission oil level.
CAUTION USED OIL CONTAINS SUBSTANCES THAT ARE HARMFUL TO THE ENVIRONMENT. DISPOSE OF USED OIL ACCORDING TO THE REGULATIONS IN FORCE.

MAIN - 39

Maintenance

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 REPLACEMENT. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FILTERING ELEMENT; THE FUEL SUPPLY SYSTEM 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 solvents, and let it dry properly. Apply a specific filter oil over all the surface.
CAUTION PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACEMENT. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FILTERING ELEMENT; THE FUEL SUPPLY SYSTEM MAY CATCH FIRE POSING A GREAT RISK FOR PEOPLE AND THE 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

MAIN - 40

Maintenance

Replacement
Rest the vehicle on its centre stand. 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 collect the engine oil.
NOTE PARK THE VEHICLE ON SAFE AND LEVEL GROUND. CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.

Unscrew and remove the cartridge engine 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 drainage plug 3. Add oil through the transmission engine oil fill opening. Screw and tighten the measuring capdipstick 1. Start the engine and let it run for several minutes. Stop the engine and let it cool down. Check the engine oil level.
CAUTION USED OIL CONTAINS SUBSTANCES THAT ARE HARMFUL TO THE ENVIRONMENT. DISPOSE OF USED OIL ACCORDING TO THE REGULATIONS IN FORCE.

Check
Park the vehicle on firm and level ground. Rest the vehicle on its centre stand. MAIN - 41

Maintenance

CAUTION

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. 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 OF THE 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.
WARNING DO 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 RECOMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.
NOTE

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

Cooling system Level check


CAUTION

MAIN - 42

Maintenance

WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANT LEVEL.
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 TO THE 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 TANK REMAINS 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 MAIN - 43

Maintenance

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 CIRCUIT.

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 indicated on the sight glass 1. MIN = minimum level. If the fluid does not reach at least the MIN reference mark:
CAUTION BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS 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 indicated.
CAUTION RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE FRONT BRAKE LEVER WHEN THE SCREWS ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COVER HAS BEEN REMOVED. PLACE A CLOTH UNDER THE BRAKE FLUID RESERVOIR TO PROTECT IT FROM ANY FLUID LEAKS.

MAIN - 44

Maintenance

Remove the cover and top up the reservoir with the recommended liquid until the correct level is reached
CAUTION DO NOT SHAKE THE VEHICLE TO AVOID BRAKE FLUID SPLASHING DURING TOP-UP. CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE. CAUTION DO NOT FILL UP THE TANK TO THE MAXIMUM, BUT JUST OVER THE ''MIN'' LEVEL. TOP-UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. IT IS ADVISABLE NOT TO TOP-UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BECAUSE YOUR RISK SPILLING FLUID WHEN CHANGING THE 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 corresponding screws 1 on the front wheel housing. SCREW it (clockwise) to raise the light beam. UNSCREW it (anticlockwise) to lower the light beam.

MAIN - 45

INDEX OF TOPICS

ELECTRICAL

SYSTEM

ELE SYS

Electrical system

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 ELE SYS - 47

Electrical system

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 ELE SYS - 48

Electrical system

R red V green Vi purple Ro pink

Components arrangement

1. Fan 2. Thermometric switch Remove the legshield to reach it.

ELE SYS - 49

Electrical system

3. Horn 4. Voltage regulator Remove the front wheel housing to reach it.

Electric characteristic
No-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.

ELE SYS - 50

Electrical system

10. Magneto flywheel 11. Automatic starter Remove the tail section to reach connectors.

Electric characteristic
Permanent magnet generator 12V - 180W Stator winding resistance 0.11 Ohm at 20 C (68 F) Off-load generated voltage > 50 V at 5000 RPM Pick-up winding resistance 10510% 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.

13. Fuel Level Sensor Remove the plastic cover under the saddle to reach it.

Electric characteristic
Full tank 10010% Ohm Empty tank 120010% Ohm

ELE SYS - 51

Electrical system

14. Thermistor Remove the helmet compartment to reach it.

Electric characteristic
Resistance at 100 C (212F) 144 Ohm Resistance at 80 C (176F) 262 Ohm Resistance at 60 C (140F) 512 Ohm Resistance at 40 C (104F) 1090 Ohm 15. HV coil Remove the rear central cover to reach it.

Electric characteristic
Secondary resistance 290010% Ohm at 20 C (68 F) Primary resistance 0.210% Ohm at 20 C (68 F)

ELE SYS - 52

Electrical system

Front side

ELE SYS - 53

Electrical system

ELE SYS - 54

Electrical system

KEY 1.Push through the hole 2. Long black clamps (290x4.5) 3.Push through the hole

ELE SYS - 55

Electrical system

KEY 1. Medium black clamps (180x4.5)

ELE SYS - 56

Electrical system

KEY 1. Medium black clamps (180x4.5)

ELE SYS - 57

Electrical system

KEY 1. Long black clamps

ELE SYS - 58

Electrical system

KEY 1.Long black clamps (290x4.5)

ELE SYS - 59

Electrical system

ELE SYS - 60

Electrical system

ELE SYS - 61

Electrical system

KEY 1. Long black clamps (290x4.5)

ELE SYS - 62

Electrical system

ELE SYS - 63

Electrical system

Back side

KEY 1. Medium black clamps (180x4.5)

ELE SYS - 64

Electrical system

KEY 1. Small black clamps (98x2.5)

ELE SYS - 65

Electrical system

KEY 1. Rubber cap 2.Medium black clamps (180x4.5)

ELE SYS - 66

Electrical system

KEY 1. Small black clamps (98x2.5)

ELE SYS - 67

Electrical system

KEY 1. Small black clamps (98x2.5) 2. Cable guide

ELE SYS - 68

Electrical system

KEY 1. Long black clamps (290x4.5)

ELE SYS - 69

Electrical system

KEY 1.Long black clamps (290x4.5)

ELE SYS - 70

Electrical system

KEY 1. Long black clamps (290x4.5)

ELE SYS - 71

Electrical system

KEY 1.Small black clamps (98x2.5)

ELE SYS - 72

Electrical system

KEY 1.Medium black clamps (180x4.5)

ELE SYS - 73

Electrical system

Conceptual diagrams Ignition

KEY: 8. Key switch 21. Main fuses 22. Auxiliary fuses 24.Battery 25. HV coil 26.Spark plug 28. CDI Control Unit 31. Pick-up 48. Engine stop switch

ELE SYS - 74

Electrical system

Battery recharge and starting

KEY: 8. Key switch 9.Front stop switch 10. Rear stop switch 19. Start-up relay 20. Starter motor 21. Main fuses 22. Auxiliary fuses 24. Battery 32. Generator 33. Voltage regulator 47. Start button 48. Engine stop switch

ELE SYS - 75

Electrical system

Level indicators and enable signals section

KEY: 1. Multiple connectors 2. Fuel Level Sensor 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

ELE SYS - 76

Electrical system

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 28. CDI Control Unit 34.Thermometric switch 35.Fan 46. Horn button

ELE SYS - 77

Electrical system

Lights and turn indicators

KEY: 3.Instrument panel 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 indicator switch 21. Main fuses 22. Auxiliary fuses 24.Battery 28.CDI Control Unit 38.Right front turn indicator

ELE SYS - 78

Electrical system

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 plug


CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 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 between terminals No. 6 (Blue-Yellow cable) and No. 8 (Blue cable). If the value measured is incorrect, repeat the check directly on the component.

ELE SYS - 79

Electrical system

Disconnect the Pick-Up connector and measure the resistance between the pin corresponding to the Blue-Yellow cable of the wiring and the ground connection on the engine. If the value measured is correct, check wiring continuity.

Electric characteristic
Pick-up winding resistance 10510% Ohm at 20 C (68 F) Coil primary check: Disconnect the connector of the control unit. Measure the resistance present between terminals No. 3 (White-Purple cable) and No. 8 (Blue cable). If the measured value is incorrect, repeat the check between the positive and negative terminals of the coil. If a correct value is measured, check wiring continuity.

Electric characteristic
Primary resistance 0.210% 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 characteristic
Secondary resistance 290010% Ohm at 20 C (68 F)

Battery recharge circuit


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

Electric characteristic
No-load recharge voltage ELE SYS - 80

Electrical system

13 15 V at 5000 rpm

Stator check
Checking the stator winding
WARNING

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 characteristic
Stator winding resistance 0.11 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 harnesses if necessary.

Recharge system voltage check


Connect the ammeter induction clamp to the voltage regulator positive terminal (Red-Orange). Measure the battery voltage and turning on the vehicle lights, with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine.

Characteristic
Generated current: 6A at 6000 rpm ELE SYS - 81

Electrical system

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 fuses
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.

ELE SYS - 82

Electrical system

1) Check fuses No. 1 and 4. 2) Check key switch and engine stop switch contacts. 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 connects the start-up relay and the starter motor (see figure).

Horn control

KEY: 1. Horn button ELE SYS - 83

Electrical system

2. Key switch 3. Horn 4.Battery 5.Main fuses 6.Auxiliary fuses


CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 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 voltage 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 ELE SYS - 84

Electrical system

2. Key switch 3.Main fuses 4.Battery 5.Auxiliary fuses 6.Automatic starter


CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 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 characteristic
Starter resistance ~30 Ohm at 20 C (68 F)

Turn signals system check

KEY: 1. Instrument panel ELE SYS - 85

Electrical system

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 indicator
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 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 panel


CAUTION

ELE SYS - 86

Electrical system

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 1) Measure the resistance in the fuel level sensor ends in the different conditions. 2) If the resistance values are correct, but the indication on the instrument panel is incorrect, check the integrity and the connections of the cable harnesses (Brown cable with pin 7 of the instrument panel connector and Grey-Green cable with pin 12 of the instrument panel connector.)

Electric characteristic
Full tank 10010% Ohm Empty tank 120010% Ohm

Lights list

KEY: 1.Instrument panel 2. Light switch ELE SYS - 87

Electrical system

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 LIGHTS
1 2 3 4 5 6 7 8 9 10 11 12 CAUTION Specification High-/low-beam bulb Tail light bulb Front turn indicator bulbs Rear turn indicator bulbs Rear tail light /stop light bulb License plate light bulb Instrument panel lighting bulb Turn indicator warning light High-beam warning light Low fuel warning light Engine oil pressure warning light High coolant temperature gauge warning light Desc./Quantity 12 V - 55 W - H7 12V - 5W 12 V - 10 W (Amber) 12 V - 10 W (White) 12 V - 5/21 W (Red) 12V - 5W LED LED LED LED LED LED

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. Tail lights line check 1) Check that bulbs and their ground connection are in working conditions (Blue cables). 2) Check fuses No. 1 and 3. 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). 2) Check fuses No. 1 and 3. 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.

ELE SYS - 88

Electrical system

Fuses
CAUTION

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

FUSE DISTRIBUTION
1 Specification Fuse No. 1 Desc./Quantity Capacity: 20A Protected circuits: Key switch, instrument panel, fan and recharge circuit. Capacity: 15 A Protected circuits: From battery to plug socket. Capacity: 15 A Protected circuits: From key switch to tail lights, stop lights, high-beam light, low-beam light, horn and instrument panel. Capacity: 7.5A Protected circuits: From key switch to automatic starter, ignition and start-up circuit.

2 3

Fuse No. 2 Fuse No. 3

Fuse No. 4

Dashboard

KEY 1. Blue high-beam warning light 2. Green turn indicators warning light 3. Fuel gauge 4. Orange low fuel warning light ELE SYS - 89

Electrical system

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 function


WARNING

THE SERVICE WARNING LIGHT IS NOT ACTIVE. WHEN THE KEY IS INSERTED, THE SERVICE COUPONS ICON SHALL BE ON FOR TWO SECONDS ONLY AFTER REACHING 50,000 KM. CARRY 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.

ELE SYS - 90

Electrical system

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 14.4014.70V Initial charge current equal to 0.30.5 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 CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MAGNESIUM MILK, BEATEN EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN

ELE SYS - 91

Electrical system

Remove the short closed tube and the caps, then pour sulphuric acid into the cells, using the type specified for batteries, with a specific gravity of 1.26, corresponding to 30 B, at a minimum temperature of 15C 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 31 B, and these values are stabilised. 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 vehicle ensuring that it is connected properly. 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 3032 B, corresponding to a specific weight of 1.261.28, must be at a minimum temperature of 15 C. A density reading below 20 B 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. ELE SYS - 92

Electrical system

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 connected to the - negative terminal while the other two red wires marked (+) are connected to the + positive terminal. Battery recharge
WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP NAKED FLAMES 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 corresponding 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. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
CAUTION

ORDINARY DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL TO THE BATTERY. 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 SHORTENS BATTERY LIFE.

ELE SYS - 93

Electrical system

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)

ELE SYS - 94

Electrical system

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)

ELE SYS - 95

INDEX OF TOPICS

ENGINE FROM VEHICLE

ENG VE

Engine from vehicle

Exhaust assy. Removal


CAUTION

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 Rest the vehicle on its centre stand. Loosen the clamp (1) fixing the exhaust silencer to the manifold. Undo and remove the three fixing 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.

ENG VE - 97

Engine from vehicle

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 radiator to the water pump and empty the system.

ENG VE - 98

Engine from vehicle

Remove the fuel inlet and delivery pipes from the fuel pump.

Remove the fuel manifold from the carburettor.

Remove the coolant temperature sensor connector.

Remove the starter motor power supply cable and the ground lead to release cable harnesses.

ENG VE - 99

Engine from vehicle

Remove the automatic starter connector 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

ENG VE - 100

Engine from vehicle

PAY SPECIAL ATTENTION WHEN POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

ENG VE - 101

INDEX OF TOPICS

ENGINE

ENG

Engine

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 transmission housing.

ENG - 103

Engine

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

ENG - 104

Engine

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
020376Y Adapter handle 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.
CAUTION REST THE COVER ON A SUITABLE SURFACE TO AVOID DAMAGING THE COVER COAT. NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE AT EVERY REFIT

Specific tooling
020376Y Adapter handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide

Baffle roller Removal


Belt support roller (only 200 cc version) ENG - 105

Engine

- 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 tooling
020455Y 10 mm guide

ENG - 106

Engine

- 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.
NOTE THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE DRIVING 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
ENG - 107

Engine

Clutch bell max. value Max. value: 134.5 mm Clutch bell standard value Standard value: 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 MUST NOT 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 SPRING LOAD.

Characteristic
Check minimum thickness 1 mm

ENG - 108

Engine

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 TOUCH THE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.

Specific tooling
020444Y009 46 x 55 wrench 020444Y010 adaptor ring

ENG - 109

Engine

- 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).
CAUTION

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

Specific tooling
020444Y009 46 x 55 wrench 020444Y011 adaptor ring

ENG - 110

Engine

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 ORING SEAL.

ENG - 111

Engine

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

ENG - 112

Engine

- Remove the roller bearing using the modular punch.

Specific tooling
020376Y Adapter handle 020456Y 24 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.

Characteristic
Half-pulley minimum diameter Minimum diameter allowed: 40.96 mm Half-pulley standard diameter Standard diameter: 40.985 mm Wear limit 0.3 mm

ENG - 113

Engine

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.

Characteristic
Moving driven half-pulley max. diameter Max. diameter allowed 41.08 mm Movable driven half-pulley standard diameter

ENG - 114

Engine

Standard diameter: 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 ring
WARNING NOTE

FIT THE BALL BEARING SO THAT THE SHIELD IS VISIBLE

Specific tooling
020376Y Adapter handle 020375Y 28 x 30 mm adaptor 020424Y Punch for fitting driven pulley roller casing

ENG - 115

Engine

Refitting the driven pulley


Driven pulley assembly - Insert the new oil seals and O-rings on the movable 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 procedure is necessary to prevent the presence of grease beyond the O-rings.
NOTE THE TORQUE SERVER CAN BE GREASED WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; IT MAY BE EASIER TO GREASE TORQUE SERVER WHEN THE BEARINGS ARE BEING SERVICED.

Specific tooling
020263Y Sheath for fitting the driven pulley

Recommended products
AGIP GREASE SM 2 Grease for C-ring of the tone wheel Soap-based lithium grease with NLGI 2 molybdenum 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.

ENG - 116

Engine

Inspecting the clutch spring


- Measure the length of the movable driven halfpulley spring, when unloaded.

Characteristic
Standard 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 vertical 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. ENG - 117

Engine

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 SURFACE SHOULD BE MOUNTED CONTACTING THE CLUTCH.
NOTE

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

Specific tooling
020444Y011 adaptor ring 020444Y009 46 x 55 wrench

Locking torques (N*m)


Clutch assembly nut on driven pulley 55 60

ENG - 118

Engine

200 VERSION

ENG - 119

Engine

Support the specific tool to compress the driven pulley spring with the control screw in vertical axis. Prepare the tool with the mediumlength 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 plastic support in contact with the clutch. Insert the driving belt in the pulley assembly observing to 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 and place the belt in the smaller diameter rolling position.

ENG - 120

Engine

Remove the driven pulley / belt assembly from the tool.


NOTE WHEN PRELOADING THE SPRING, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. NOTE FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED CONTACTING THE CLUTCH.

Specific tooling
020444Y Tool for fitting/removing the clutch on the driven pulley 020444Y011 adaptor ring 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 ENG - 121

Engine

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
020368Y driving pulley lock wrench

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.

ENG - 122

Engine

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 figure. Check that the rollers are not damaged or worn. Check that the guide sliders for the roller contrast plate are not worn.

ENG - 123

Engine

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.
CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic
roller (200): Minimum diameter admitted 20 mm roller (125): Minimum diameter admitted 18.5 mm sliding bushing: Minimum diameter admitted 25.95 mm movable driving half-pulley bushing: Max. diameter admitted 26.12 mm roller (200): Standard Diameter 20.5 20.7 mm roller (125): Standard Diameter 18.9 19.1 mm sliding bushing: Standard Diameter 25.959 25.98 mm movable driving half-pulley bushing: Standard Diameter 26.000 26.021 mm

Refitting the driving pulley


125 VERSION Refit the removed Bendix correctly on its seat.

ENG - 124

Engine

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 FREE SO THAT THE PULLEY IS NOT INCORRECTLY TAUTENED.

Specific tooling
020368Y driving pulley lock wrench

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 assembly to the engine.

ENG - 125

Engine

ENG - 126

Engine

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 tooling
020423Y 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. ENG - 127

Engine

- 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

ENG - 128

Engine

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
020376Y Adapter handle 020477Y 37-mm Adaptor 020483Y 30 mm guide 020359Y 42 x 47-mm adaptor 020489Y Stud bolt set for hub cover support

ENG - 129

Engine

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
020376Y Adapter handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide

ENG - 130

Engine

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.

ENG - 131

Engine

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
020376Y Adapter handle 020360Y 52 x 55-mm adaptor 020483Y 30 mm guide

ENG - 132

Engine

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 BEARING ON THE COVER.
NOTE

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

WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, THE CRANKCASE SHOULD, AS FAR AS POSSIBLE, BE SUPPORTED ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.

Specific tooling
020150Y Air heater support 020151Y Air heater 020412Y 15 mm guide 020376Y Adapter handle 020359Y 42 x 47-mm adaptor 020363Y 20 mm guide

ENG - 133

Engine

Refitting the hub bearings


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

ENG - 134

Engine

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

ENG - 135

Engine

Flywheel cover Removing the hub cover


- Remove both clamps, both sleeves and empty the cooling system. - Remove the 4 retainers and the flywheel cover

ENG - 136

Engine

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 stator
NOTE THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REFERENCE PIN AS SHOWN 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 CENTRING DOWELS ARE FITTED.

ENG - 137

Engine

Flywheel and starting Removing the flywheel magneto


- Lock the Flywheel rotation using the calliper spanner tool. - Remove the nut. - Take out the flywheel.
CAUTION

USING A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS.
NOTE

THE 200CC VERSION FLYWHEEL IS SUPPLIED WITH MORE INERTIA MASS.

ENG - 138

Engine

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.
NOTE A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED.

Specific tooling
020565Y Flywheel lock calliper spanner

Locking torques (N*m)


Flywheel nut 54 60

ENG - 139

Engine

Refitting the starter motor


- Fit and lubricate a new O-ring on the starter motor. - 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 described in the flywheel cover chapter. - Loosen the 3 screws and remove the air intake manifold.
NOTE THE 125 CC VERSION IS PROVIDED WITH TAMPERPROOF 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. ENG - 140

Engine

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.

ENG - 141

Engine

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.

ENG - 142

Engine

Removing the cylinder head


- Remove the spark plug. - Remove the 2 side retainers indicated in the figure. - 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.
NOTE IF NECESSARY, THE HEAD MAY BE REMOVED TOGETHER WITH THE CAMSHAFT, ROCKING LEVER PINS AND MOUNTING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT TAKING OUT THE CHAIN AND THE CHAIN 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. ENG - 143

Engine

CAUTION

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

Specific tooling
020382Y011 adaptor for valve removing tool 020382Y Tool for removing valve cotters fitted with part 012 020306Y Punch for fitting the valve sealing rings

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. ENG - 144

Engine

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 STANDARD DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING.

Characteristic
Checking the rod small end: Max. diameter 15.030 mm Checking the rod small end: Standard diameter 15+0.015 +0.025 mm

ENG - 145

Engine

Inspecting the wrist pin


Check the pin outside diameter. Calculate the rod small end - pin coupling clearance. Measure the diameter of the bearings on the piston. Calculate the pin - piston coupling clearance.
NOTE THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS.

Characteristic
Pin diameter: Standard clearance 0.015 0.029 mm Pin diameter: Standard diameter 14.996 15.000 mm Pin seat diameter on piston: Standard diameter 15.001 15.006 mm Pin seat diameter on piston: Standard clearance 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 ENG - 146

Engine

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/Assembly clearances"

ENG - 147

Engine

Inspecting the cylinder


Using a bore meter, measure the cylinder 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 according 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 original angle. The cylinder surface roughness should be 0.9 micron. This is essential for a good seating of the sealing rings, which in turn minimises 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 also 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.
NOTE

BEFORE REPLACING ONLY THE PISTON RINGS, MAKE SURE THAT COUPLING CLEARANCE BETWEEN THE PISTON RINGS AND ITS GROOVES, AND THAT BETWEEN THE PISTON AND ENG - 148

Engine

THE CYLINDER ARE AS SPECIFIED. IN ANY CASE, NEW PISTON SEALING RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE 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.
CAUTION

USING A HAMMER MAY DAMAGE THE RINGS HOUSINGS.


NOTE

THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.

Specific tooling
020430Y Tool for fitting the pin snap rings 020454Y Tool to fit pin snap rings (200 - 250)

ENG - 149

Engine

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 thickness 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.
NOTE MEASURE PROTRUSION ON 125 ENGINES, AND RECESS ON 200 ENGINES.

ENG - 150

Engine

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 facing 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 120 as shown in the figure. - Lubricate the components with engine oil. - 200 engines use the top ring with an L-shaped section.
NOTE THE 2 PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT SECTION. THIS IS TO OBTAIN A BETTER 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 AND LUBRICATE THE CYLINDER LINER.

Specific tooling
020393Y Piston fitting ring 020287Y Band for fitting the piston on the cylinder

ENG - 151

Engine

Inspecting the cylinder head


- Using a trued bar and a thickness gauge, check that the cylinder head surface is not worn or distorted. Maximum run-out allowed: 0.05 mm - Check that the camshaft and the rocker pin bearings show no signs of wear. - Check that the cylinder head cover surface, the intake manifold and exhaust manifold are not worn.

Characteristic
bearing A 12.000 12.018 bearing B 20.000 20.021 bearing C 37.000 37.025

ENG - 152

Engine

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 assembly.

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.

ENG - 153

Engine

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.

Characteristic
Valve 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. ENG - 154

Engine

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.
CAUTION

DO NOT CHANGE THE VALVE FITTING POSITION (RH - LH).

Characteristic
Valve 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 LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
NOTE

DO NOT CHANGE THE VALVE FITTING POSITION

Characteristic
Valve 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: ENG - 155

Engine

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

ENG - 156

Engine

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, compress the springs and insert the cotters in their seats.
NOTE

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

Specific tooling
020306Y Punch for fitting the valve sealing rings 020382Y Tool for removing valve cotters fitted with part 012 020382Y011 adaptor for valve removing tool

ENG - 157

Engine

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
ENG - 158

Engine

Rocking levers inside diameter: Standard diameter 12.000 12.011 mm Rocking lever pins diameter: Standard diameter 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 : 19.950 mm Camshaft check: Minimum diameter admitted Bearing A : 36.94 mm Camshaft check: Standard diameter Bearing B : 19.959 19.98 mm Camshaft check: Standard diameter Bearing A : 36.95 36.975 mm

ENG - 159

Engine

Refitting the head and timing system components


- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the 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 torque.

ENG - 160

Engine

- 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 prescribed 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 mm
NOTE GREASE THE END-STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)


Timing chain tensioner support screw 11 13 Spark plug 12 14 Starter ground screw 7 8.5 Timing chain tensioner pad screw 10 14 Starter ground bell screw 11 15 Timing chain tensioner central screw 5 6 Camshaft retention plate screw 4 6 ENG - 161

Engine

- 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 71 Nm - Carry out an angle rotation of 180 (2 rotations of 90each) - 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 CLEAN USING A JET OF COMPRESSED AIR.

Locking torques (N*m)


Timing chain tensioner support screw 11 13

ENG - 162

Engine

ENG - 163

Engine

Refitting the intake manifold


- Assemble the inlet manifold and tighten the 3 screws.
NOTE FOR THE SPECIAL SCREWS OF THE 125 CC VERSION, USE COMMERCIAL INSERTS AND INSERT HOLDERS.

Crankcase - crankshaft Splitting the crankcase halves


engine crankcase opening

ble>
- First remove the following units: transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil seals as described in the transmission chapter. Remove the oil sump, the bypass, the chain compartment cover and the oil pump as described in the lubrication chapter. - Remove the flywheel cover with the water pump, the flywheel, 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.

ENG - 164

Engine

- Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with a specific tool dial gauge. - Higher clearances are signs of wear on the supporting surfaces 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 shown in the figure. - 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 crankshaft width as shown in the figure. Shimming (only 200 cc)

ENG - 165

Engine

- Check shim washer thickness. - 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 machining on the crankcase. - Check the diameters of both crankshaft bearings according to the axes and surfaces shown in the figure. Halfshafts are classified in two categories, Cat 1 and Cat 2, as shown in the chart below. CAUTION THE CRANKSHAFT CAN BE REUSED WHEN ITS WIDTH IS WITHIN THE STANDARD VALUES AND SURFACES SHOW NO SIGNS OF SCORING. CAUTION WHEN OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS. CAUTION WHEN SEPARATING THE CRANKCASE KEEP THE CRANKSHAFT IN ONE OF THE CRANKCASE HALF. THE CRANKSHAFT MIGHT ACCIDENTALLY FALL IF THIS RULE IS NOT OBSERVED. NOTE IN CASE OF REUSE, KEEP THE ORIGINAL FITTING POSITION. NOTE WHEN MEASURING THE CRANKSHAFT WIDTH, MAKE SURE THAT THE MEASUREMENTS ARE NOT MODIFIED BY THE COUPLING SPOKES WITH THE CRANKSHAFT BEARINGS. NOTE The 200 cc version crankshaft is fitted with two steel shim washers. Take note of the fitting position.

Specific tooling
020262Y Crankcase splitting strip

Characteristic
Camshaft bearings: Standard diameter: Cat. 2 29.000 29.006 Camshaft bearings: Standard diameter: Cat. 1

ENG - 166

Engine

28.994 29.000 Engine crankcase opening: Standard thickness 2.175 2.225 mm Crankshaft width with shim washers: standard sizes 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: Standard 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. Therefore, the connecting cannot be replaced either and, when cleaning the crankshaft, be very careful that no impurities get in through the shaft lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted. - A wrong installation of a cap can seriously affect the bushing lubrication pressure.
NOTE CRANKCASE BEARINGS ARE NOT GRINDABLE .

ENG - 167

Engine

Specific tooling
020074Y Support base for checking crankshaft alignment

Characteristic
Maximum off-line allowed: A = 0.15 mm
B = 0.01 mm C = 0.01 mm D = 0.10 mm

CRANKSHAFT
Titolo Crankshaft alignment Durata/Valore

ALIGNMENT

Testo Breve (< 4000 car.)

Indirizzo Immagine

Measure the flows on both X-Y axles

STANDARD DIAMETER (125 - 200


Name Cat. 1 Cat. 2 Description Dimensions 28.998 29.004 29.004 29.010

CC)

Initials

Quantity

Maximum off-line allowed: A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm

Specific tooling
020335Y Dial gauge magnetic support ENG - 168

Engine

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.
NOTE

THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKAGE CAN CONSIDERABLY CAUSE A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CONNECTING ROD.
NOTE

THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET: THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE HAS BEEN MADE TO REDUCE OIL TEMPERATURE. JET CLOGGING IMPAIRS HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CONNECTING ROD.

ENG - 169

Engine

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 prescribed 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 crankshaft 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 prescribed 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.

ENG - 170

Engine

- Insert the pre-filter and its cover on the engine. Tighten to the specified torque.
NOTE FAILURE TO USE THE SPECIFIC TOOL MAY RESULT IN AN INCORRECT DEPTH POSITION AND, AS A CONSEQUENCE, IN INADEQUATE OIL SEALING.

Specific tooling
020425Y Punch for flywheel side oil seal

Locking torques (N*m)


Screws for engine crankcase internal bulkhead (transmission-side half shaft) 4 6 Oil filter fitting on crankcase 27 33 Engine crankcase coupling screws 11 13 engine oil drainage plug/mesh filter 24 30

Lubrication Conceptual diagrams


LUBRICATION CIRCUIT

ENG - 171

Engine

ENG - 172

Engine

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 ~90C, check that the oil pressure is between 0.5 1.2 atm. - With the engine idling at 6000 rpm and the oil temperature at ~90C, 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 OIL FILTER IN GOOD CONDITION.

Specific tooling
020193Y Gauge for oil pressure check 020434Y Fitting for oil pressure check 020331Y Digital multimeter

ENG - 173

Engine

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 SURE THAT 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 pump cover screws 0.7 0.9

ENG - 174

Engine

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 crankshaft 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.
CAUTION DO NOT LUBRICATE THE KEYING SURFACE ON THE ENGINE CRANKCASE CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. ONCE THE POSITION IS REACHED, DO NOT RETRACT THE OIL GUARD. FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL GUARD COUPLING SHEATH. CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP DRIVING CHAIN

Specific tooling
020622Y Transmission-side oil seal punch

ENG - 175

Engine

- Undo the 2 clamping screws in the figure and remove 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 Oring. - Remove the oil pump by unscrewing the 2 screws indicated in the figure. - Remove the sealing gasket.
NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.

Inspection
- Remove the two screws and the oil pump cover. - Remove the 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. ENG - 176

Engine

- 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.

Characteristic
Rotor 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

ENG - 177

Engine

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 "Transmission" 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 gasket 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.

Characteristic
By-pass check: Standard length 54.2 mm

ENG - 178

Engine

Refitting the oil sump


- Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the 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 regarding lubrication of the crankshaft and connecting rod.

Locking torques (N*m)


Oil sump screws 10 14

ENG - 179

Engine

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.
NOTE

A MALFUNCTIONING ONEWAY VALVE CAN RESULT IN RUBBER SLEEVE AND FILTER OVERHEATING.
NOTE

ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING

Specific tooling
020329Y 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. ENG - 180

Engine

- 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 IN THE MUFFLER).INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT IN CATALYTIC CONVERTER MALFUNCTION
NOTE

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

Specific tooling
020329Y MityVac Vacuum pump

ENG - 181

Engine

ENG - 182

Engine

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 THE FILTER 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.

ENG - 183

Engine

Remove the clamp and slide off the heater pipe 1. Plug the heater pipe 1 so that coolant 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 CAUTION SO AS NOT TO DAMAGE ANY COMPONENT. Release the carburettor from the sleeve 3 and partially remove it.
CAUTION OPERATE WITH CAUTION. DO NOT DAMAGE THE FIXING TONGUES 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 carburettor.

ENG - 184

Engine

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.
NOTE THIS LAST OPERATION IS NECESSARY SO AS NO TO EMPTY THE COOLING SYSTEM.

- Remove the protection, the bracket and the starter by undoing the screw shown in the figure.

ENG - 185

Engine

- Remove the 2 screws and the starter support together 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.
WARNING UPON REMOVING THE CARBURETTOR COVER, PAY ATTENTION NOT TO RELEASE THE SPRING ACCIDENTALLY.

ENG - 186

Engine

- Remove the vacuum valve and the diaphragm;

- Unscrew the bayonet joint 1/8 of a turn and remove it; take out the spring and the vacuum valve needle.

- Remove the 4 screws shown in the figure.

- Remove the chamber together with the accelerating pump, its control and gasket.

ENG - 187

Engine

- Remove the sealing gasket. - Remove the intake and outlet valves of the accelerating pump from the float chamber
NOTE BE CAREFUL THAT THE ACCELERATING PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL. NOTE AVOID REMOVING THE PISTON OF THE ACCELERATING PUMP 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.

ENG - 188

Engine

- Remove the diffuser.

- Remove the sprayer.


NOTE WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED INTO ITS POSITION, DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.

ENG - 189

Engine

- Remove the minimum jet.

- Remove the minimum flow set screw and the spring.


CAUTION DO NOT TRY TO REMOVE PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, NEEDLE SEAT, STARTER NOZZLE, TRAP COVER FOR PROGRESSIONS AND INLET NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT.DO NOT REMOVE THROTTLE-TO-SHAFT CONNECTING SCREWS. THE FIXING SCREWS ARE CAULKED AFTER BEING FITTED AND REMOVING THEM DAMAGES THE SHAFT.

Adjusting the idle


The engine does not require frequent idle speed adjustments, but it is essential to strictly follow certain 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.

ENG - 190

Engine

Start the engine and before adjusting idle speed, make sure that the oil temperature 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 adjustments, however it is very important to make any adjustments fully respecting some standards. - Before adjusting the carburettor make sure to respect the lubrication requirements, valve clearance, and complying timing, spark plug should be in optimum conditions, air filter clean and sealed, and the exhaust system tight. - Warm up the engine by running it at least 5 minutes at approximately 50 kph. - Connect the vehicle to the exhaust fumes analyser inserting the probe into a sealed extension pipe placed at the muffler exit end. - Connect a millimetre thermometer (020331y) on the sump, using a cover with oil expressly prepared for probes. - Start the motor and before adjusting the idle speed make sure that the oil temperature is between 70 80C. - 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.

ENG - 191

Engine

- When the oil temperature, the numbers of revs and the percentage of carbon monoxide are respected the idle carburetion is considered correct. From the analyser we can draw further information: - carbon dioxide percentages (CO2), the percentage of carbon dioxide has an inverted course compared to the percentage of(CO), values over 12.5% are considered correct. Non complying values indicate lack of tightness in the exhaust system. - Unburned hydrocarbons (HC) are measured in parts per million (PPM). The HC value decreases while the rpm increases; with the engine at idle it is normal to detect 200 400 PPM, these emission values are deemed normal for an engine with a diagram of distribution for motorcycles. Higher values can cause loss of engine blows as the mixture is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. - If it were difficult to ???? adjustment CO check accurately: - That the carburettor is clean - That the automatic starter is efficient - Tapered pin housing efficiency - Tank level adjustments
NOTE THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED. CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN ALSO READ RPM OVER 6000 8000

ENG - 192

INDEX OF TOPICS

SUSPENSIONS

SUSP

Suspensions

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.

SUSP - 194

Suspensions

Rest the scooter on its centre stand. Place a support under the chassis. Remove the brake calliper. Loosen the pin locking screw.
CAUTION UPON REMOVING/REFITTING, PAY ATTENTION NOT TO DAMAGE 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, OTHERWISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT, RESULTING IN BRAKE FLUID LEAKAGE. 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 bearings. Collect the internal spacer 5. Clean the inside of the hub thoroughly.

SUSP - 195

Suspensions

Wash all the parts with clean detergent.


CAUTION UPON REFITTING, USE A BUFFER WITH A DIAMETER EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO INSERT THE BEARINGS. DO NOT HIT THE BALLS AND/OR THE INTERNAL RING. MAKE SURE THE FOLLOWING COMPONENTS 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.
CAUTION CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS, 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 eccentricity. Replace the pin 2 if the eccentricity exceeds the limit value.

Characteristic
Maximum eccentricity: 0.25 mm

RIM Using a dial gauge, check that the radial eccentricity 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 replaced, the value is not within the specified limit.

Characteristic
Maximum radial and axial eccentricity: SUSP - 196

Suspensions

2 mm Check the tyre conditions.


CAUTION CHECK TYRE TREAD FOR WEAR. BADLY WORN TYRES COMPROMISE TRACTION AND VEHICLE HANDLING. REPLACE TYRES WHEN WORN OR IF THERE IS A PUNCTURE BIGGER THAN 5 MM IN THE TREAD. SOME TYRE TYPE-APPROVED FOR THIS VEHICLE FEATURE WEAR INDICATORS. CHECK THAT THE INFLATION VALVES 1 HAVE THEIR CAPS FITTED IN ORDER TO AVOID UNEXPECTED FLAT TYRES. BALANCE THE WHEEL AFTER A TYRE IS MENDED.

Handlebar Removal
Remove the front handlebar cover. 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 electric controls and release the handlebar from the cable harness.

SUSP - 197

Suspensions

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 steering tube.

Remove the throttle grip from the handlebar.

To refit, carry out removal operations but in reverse order

Locking torques (N*m)


Locking torque value in Nm

SUSP - 198

Suspensions

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 SUSP - 199

Suspensions

20. Right stem 21. Right wheel holder 22. Locking screw

Removal
STEM REMOVAL Remove the front wheel. Remove the front mudguard. Undo and remove the two screws 1.
NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE WHEEL HOLDER STEM - SLEEVE, BUT THEY APPLY 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).
NOTE GET A COLLECTING CONTAINER BEFORE CARRYING OUT THESE OPERATIONS. CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL. DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT.

SUSP - 200

Suspensions

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 minutes so that the oil deposited on it drips off.

SUSP - 201

Suspensions

Drain off the oil into the collecting container by pumping it out with the stem.

WHEEL HOLDER STEMS SLEEVES REMOVAL Drain off the oil. Place the stem in a vice fitted with protection jaws (aluminium).

Undo and remove the lower screw 1.

Remove the stem and collect the centring bushing.


NOTE BE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIOR WHEN REMOVING THE DIFFERENT COMPONENTS.

SUSP - 202

Suspensions

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.

SUSP - 203

Suspensions

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 BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.

Characteristic
Bending limit: 0.2 mm

SUSP - 204

Suspensions

Check that there are no damages and/ or cracks; otherwise, replace it. If there are signs of excessive wear or damage, replace the affected component. 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.
CAUTION BE EXTREMELY CAREFUL SO THAT NO FOREIGN BODIES GET INTO THE SLEEVE OR THE WHEEL HOLDER STEM.

Insert the washer.


NOTE SPREAD A THIN LAYER OF FORK OIL ON GASKETS AND BUSHINGS BEFORE REFITTING THEM.

SUSP - 205

Suspensions

Insert the oil seal.

Fit the Seeger ring.

Fit the dust guard.

Insert the pumping member and the spring in the stem.

SUSP - 206

Suspensions

Fit the components below on the sleeve in the following order: the centring 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.

SUSP - 207

Suspensions

Pour fork oil into the wheel holder stem sleeve unit.
CAUTION NEVER 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.

SUSP - 208

Suspensions

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.

SUSP - 209

Suspensions

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 necessary.
CAUTION CHECK THAT THE COMPONENTS ARE IN GOOD CONDITIONS. CAUTION APPLY GREASE ON BALL CONTACT AREAS ON BOTH SEATS 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; SUSP - 210

Suspensions

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

SUSP - 211

Suspensions

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

Removal
WARNING

IT IS NOT NECESSARY TO REMOVE THE SWINGING ARM IN ORDER TO SERVICE IT. SUSP - 212

Suspensions

- 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 released, do so with the chassis-side swinging arm, working from both sides of the vehicle. - Unscrew the nut and collect the washer.

SUSP - 213

Suspensions

- Slide off the pin connecting it to the chassis.

- Remove swinging arm by sliding it off towards the front.

Overhaul
WARNING

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.

Characteristic
Axial clearance between both swinging arms Min: 0.6 ; Max: 1.2 mm

SUSP - 214

Suspensions

- Check clearances on the connection between the chassis-side arm and the chassis using a thickness gauge. - If values non-conforming with those specified are measured, remove the arm and replace the Teflon spacer bushings.

Characteristic
Clearance 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 silentblock. - Check that they are not broken. Otherwise, replace 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 18 punch 020244Y 15 punch

Recommended products
AGIP 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.

SUSP - 215

Suspensions

Refitting
- Follow the removal steps but in reverse order. - Tighten to the prescribed torque.

LINK ROD
Name Connecting rod to chassis retainer Connecting rod to engine retainer Chassis connecting rod on engine connecting rod retainer Silent-block on chassis retainer Torque in Nm 6020% 4020% 6020% 5020%

Shock absorbers Removal


Unscrew the upper nut and remove the screw.

SUSP - 216

Suspensions

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.

To refit, carry out removal operations but in reverse order

Centre-stand
Remove the two springs indicated.

Undo the indicated screw and slide off the U-bolt fixing screw.

SUSP - 217

Suspensions

To refit, carry out removal operations but in reverse order

SUSP - 218

INDEX OF TOPICS

BRAKING SYSTEM

BRAK SYS

Braking system

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

BRAK SYS - 220

Braking system

Removal
Undo the two screws indicated and remove the brake calliper.

If you want to replace the calliper, undo the coupling screw from the pipe to the calliper.

To refit, carry out removal operations but in reverse order

Locking torques (N*m)


Calliper on muffler plate retainer 2520%

Front brake calliper Removal


Undo the two screws indicated and remove the brake calliper.

BRAK SYS - 221

Braking system

If you want to replace the calliper, undo the coupling screw from the pipe to the calliper.

To refit, carry out removal operations but in reverse order

Locking torques (N*m)


Calliper on fork retainer 2520%

Rear brake disc Removal


Remove the rear wheel. Undo and remove the five brake disc screws. Remove the brake disc.
CAUTION UPON REFITTING, APPLY THE RECOMMENDED PRODUCT ON THE THREADING OF THE BRAKE DISC SCREWS.

Recommended products
LOCTITE 243 Loctite adhesive to assembly cylindrical 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.

Characteristic
Minimum value for brake disc thickness: 3.6 mm

BRAK SYS - 222

Braking system

Using a dial gauge, check that disc oscillation does not exceed the tolerance; otherwise, replace it.

Characteristic
Brake disc oscillation tolerance: 0.3 mm

Front brake disc Removal


Remove the front wheel. Undo and remove the five brake disc screws. Remove the brake disc.
NOTE SCREW ALL THE SCREWS MANUALLY AND TIGHTEN THEM OPERATING DIAGONALLY CAUTION UPON REFITTING, APPLY THE RECOMMENDED PRODUCT ON THE THREADING OF THE BRAKE DISC SCREWS.

Recommended products
LOCTITE 243 Loctite adhesive to assembly cylindrical 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.

Characteristic
Minimum value for brake disc thickness: 3.6 mm

BRAK SYS - 223

Braking system

Using a dial gauge, check that disc oscillation does not exceed the tolerance; otherwise, replace it.

Characteristic
Brake 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 LEAKAGE.

BRAK SYS - 224

Braking system

Check friction material for appropriate thickness. If thinner than the minimum value, replace it.

Characteristic
Friction material minimum thickness 1.5

In case of uneven wear, replace the brake pads when the friction material thickness difference is 0.5 mm
CAUTION

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

Refitting
CAUTION

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.

BRAK SYS - 225

Braking system

Slide off the pin.

Remove the spring.


CAUTION THE ARROW STAMPED ON THE SPRING MUST ALWAYS BE TURNED IN THE RIDING DIRECTION.

Slide off the brake pads.

Check friction material for appropriate thickness. If thinner than the minimum value, replace it.

Characteristic
Friction material minimum thickness 1.5

BRAK SYS - 226

Braking system

In case of uneven wear, replace the brake pads when the friction material thickness difference is 0.5 mm
CAUTION

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

Refitting
CAUTION

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 calliper 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 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 air-bubble free.
NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF

BRAK SYS - 227

Braking system

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 calliper 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 several times, keeping it completely operated afterwards. Loosen the bleed valve 1 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 bubbles.
NOTE

WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE 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.

BRAK SYS - 228

INDEX OF TOPICS

COOLING

SYSTEM

COOL SYS

Cooling system

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

COOL SYS - 230

Cooling system

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 connector 2 and jump it. The electric fan should switch on.

COOL SYS - 231

Cooling system

Undo and remove the screw 1 fixing the radiator.

Locking torques (N*m)


M6 fixing screw for radiator (on plastic) 6 (4.44
ftlb)

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 (ohmmeter function) to the thermal switch 1 as shown in the picture. Immerse the thermal switch in a container 3 with coolant. In the same container, immerse a thermometer 4 ranging from 0 150C (32 302F). 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.

COOL SYS - 232

Cooling system

COOLANT TEMPERATURE C (F) / RESISTANCE


Specification below 90 (194) Above 90 (194)

VALUES

(OHM)

Desc./Quantity Infinite 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.
NOTE BEFORE EMPTYING THE COOLING SYSTEM, PREPARE A COLLECTING CONTAINER OF A MINIMUM CAPACITY OF 1.8 LITRES (0.39 GAL).

Loosen the clamp and remove the radiator-pump pipe and allow the coolant to drain into the collecting container.

Thermostat

COOL SYS - 233

Cooling system

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 (ohmmeter function) to the thermistor 2 as shown in the figure. Immerse the thermistor in a container 11 with oil. In the same container, immerse a thermometer 12 ranging from 0 + 150 C (32 + 302F). Place the container on a cooker 13 and heat the fluid slowly.

COOL SYS - 234

Cooling system

Check the temperature indicated in the thermometer and the value of the thermistor indicated in the tester. Check that the thermistor varies according to the temperature as indicated.

OIL TEMPERATURE C (F) / RESISTANCE VALUE OHM


Specification 50 (122F) 85 (185F) CAUTION Desc./Quantity approximately 226 34 approximately 64 7

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

COOL SYS - 235

INDEX OF TOPICS

CHASSIS

CHAS

Chassis

Seat
Undo and remove the four screws. Remove the saddle.

Rear rack
Lift the saddle. Undo and remove the four screws.

Slide off the screw cover cap. Undo and remove the screw. Remove the luggage rack.

CHAS - 237

Chassis

Driving mirrors
Loosen the nut indicated.
CAUTION THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCKWISE.

Rear handlebar cover


Remove the front handlebar cover. Undo the two screws indicated. Disconnect the connector powering the instrument panel.

Instrument panel
Remove the front handlebar cover. Undo the two screws indicated. Disconnect the connector powering the instrument panel.

Front handlebar cover

CHAS - 238

Chassis

Undo the two screws indicated.

Operating from both sides of the vehicle, 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.

CHAS - 239

Chassis

Undo and remove the two screws.

Remove the central inspection cover by sliding it off its hooks.

Legshield
Operating on both sides, undo and remove the screw.

Remove the front case by sliding it off its hooks, being careful with the tongues and related fitting slots.

CHAS - 240

Chassis

Remove the front mudguard. Remove the front wheel. Operating from both sides, undo and remove the five screws.
CAUTION PLACE A SUPPORT UNDER THE CHASSIS SO THAT THE FRONT WHEEL DOES NOT TOUCH THE GROUND.

Operating from both sides, undo and remove the three screws.

Undo and remove the two screws.

Move the external legshield forwards and disconnect front headlamp connector.

CHAS - 241

Chassis

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 front central cover. Operating from both sides, undo and remove the screw.

Remove the handlebar cover. Undo and remove the two screws. Slide off the bag hook.

CHAS - 242

Chassis

Insert the key in the glove-box lock, turn it clockwise and open the compartment. Undo and remove the four screws.

Close the glove-box. Operating from both sides, undo and 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. Operating on both sides, undo and remove the rear screw of the footrest.

CHAS - 243

Chassis

Operating on both sides, undo and remove the two screws of the footrest.

Remove the battery. Unscrew and remove the bolt inside the battery compartment. Operating from both sides, undo and 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.
NOTE THESE OPERATIONS REFER TO ONLY ONE PASSENGER FOOTREST BUT THEY APPLY TO BOTH. NOTE THIS OPERATION IS NECESSARY ONLY TO REMOVE THE METAL PART OF THE FOOTREST. TO REMOVE FAIRINGS, JUST REMOVE THE PASSENGER FOOTREST RUBBER.

CHAS - 244

Chassis

Side fairings
Left and right fairings removal Remove the rear central cover. Undo and remove the screw.

Undo the two screws and remove the passenger footrest rubber.

Undo and remove the screw.

Push aside the tail section. Remove the fairing by sliding it off the hooks, being careful with the tongues and related fitting slots.

CHAS - 245

Chassis

Air filter
Remove the left side fairing. Remove the helmet compartment. 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 cover. Remove the filter casing.

Tail guard
Remove the rear central cover. Remove the luggage rack. Operating on both sides, undo and remove the four.

CHAS - 246

Chassis

Undo and remove the two screws inside the helmet compartment.

Operating on both sides, undo and remove the screw.

Undo and remove the three fixing screws.

CHAS - 247

Chassis

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.

Undo the two screws indicated and remove the tail section clamp.

Rear mudguard
Undo and remove the three screws.

CHAS - 248

Chassis

Undo the three screws and remove license plate.

Undo and remove the screw.

Undo and remove the screws indicated.

Undo the screw and slide off the license plate light backwards.

CHAS - 249

Chassis

Disconnect the license plate light connector.

Remove the rear mudguard.

Should the rear mudguard holder frame be removed before taking out the rear mudguard proceed as follows: Undo and remove the two screws.

Helmet bay
Remove the saddle Remove the luggage rack. Remove the tail section. Undo the two screws indicated.

CHAS - 250

Chassis

Working on both sides of the vehicle, undo the screw indicated and collect the washer. Remove the helmet compartment.

Front mudguard
Operating from both sides, undo and remove the two screws.

Slide off the front mudguard forwards.

Fuel tank
Remove the saddle Remove the luggage rack. Remove the tail section. Remove the helmet compartment. Disconnect the fuel level sensor power connector. Release the tank from the fuel pipes.

CHAS - 251

Chassis

Undo the two screws indicated.

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

Disconnect the two thermal switch connectors.

Loosen the clamps and remove the three pipes.

CHAS - 252

Chassis

Undo and remove the screw. Slide off the radiator upwards.

Expansion tank
Drain off the cooling system: Remove the front central cover. Remove the shield back plate. Loosen and remove the clamp.

Loosen and remove the clamp.


NOTE UPON REFITTING, REPLACE THE REMOVED CLAMPS WITH NEW ONES.

CHAS - 253

Chassis

Operating from both sides, undo and remove the screw. Remove the expansion tank.

Lower cover
Undo and remove the rear screw.

Undo and remove the two side screws.

Undo and remove the two screws.

CHAS - 254

Chassis

Undo and remove the screw fixing it to the legshield on the front wheel housing. Undo and remove the screw.

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 sections. To do this, proceed as follows: Undo and remove the two screws. Slide off the lower shield to separate it into a right and a left section.

CHAS - 255

INDEX OF TOPICS

PRE-DELIVERY

PRE DE

Pre-delivery

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 DE - 257

Pre-delivery

- 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 BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION

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

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION 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. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A 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 DE - 258

Pre-delivery

- 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 DE - 259