Page 1 WORKSHOP MANUAL GPR 125 4-stroke...
Page 2: Table Of Contents
CONTENTS INTRODUCTION ..............SAFETY REGULATIONS ............MAINTENANCE REGULATIONS ........SPECIAL TOOLS FOR THE ENGINE ........SPECIAL TOOLS - CHASSIS ..........TECHNICAL DATA ............... TIGHTENING TORQUES ............. PDI (Pre-delivery inspection) ..........LOCATION OF ELEMENTS ..........REMOVING BODYWORK ELEMENTS ........ PERIODICAL MAINTENANCE TABLE ......... LUBRICATION POINTS ............
Page 3: Table Of Contents
CONTENTS DIAGRAM OF THE SYSTEM ..........DESCRIPTION OF THE SYSTEM AND CHECKING OF ELEM ..RENEWING THE WATER PUMP OIL SEAL ......DIAGRAM OF THE SYSTEM ..........DESCRIPCIÓN OF THE LUBRICATION SYSTEM ....INSPECTING THE WHEELS ........... FRONT WHEEL ............... FRONT SUSPENSION ............
Page 4: Introduction
0 - INTRODUCTION This manual has been produced by Nacional Motor, S.A.U. for use by DERBI dealer and sub-agency works- hops. It is assumed that those using this publication for training purposes and for repairing DERBI machines have a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Signifi- cant variations in the characteristics of the machines or in the specific repair operations will be communicated by means of updates to this manual.
Page 5 0 - INTRODUCTION The aim of this manual is to provide the mechanic with a handy and easy to use reference source. It contains comprehensive explanations of all the installation, extraction, dismantling, assembly, repair and checking procedures organized step by step in sequence. Each chapter is divided into sections whose titles appear at the top of each page.
Page 6 0 - INTRODUCTION VIEWS OF THE MACHINE RIGHT-HAND SIDE (facing forwards) LEFT-HAND SIDE (facing forwards) Whenever Right-hand or Left-hand Side are specified in this manual, it N.B. is understood as meaning facing forward (i.e. in the riding direction).
Page 7 0 - INTRODUCTION IDENTIFICATION OF THE MACHINE FRAME SERIAL NUMBER VTHRG1A1Axxxxxxxx The frame serial number is located to the right of the steering column. MANUFACTURER’S PLATE The manufacturer’s plate is located to the right of the steering column. It includes information about the exhaust system’s noise emissions (useful in MOT inspec- tions).
Page 8 1 - GENERAL INFORMATION 1 - GENERAL INFORMATION 1.1 - SAFETY REGULATIONS ............1.2 - MAINTENANCE REGULATIONS ..........1.3 - SPECIAL TOOLS FOR THE ENGINE ........1.4 - SPECIAL TOOLS FOR THE CHASSIS ........1.5 - TECHNICAL DATA ..............1.6 - TORQUE TIGHTENING VALUES ..........
Page 9: Safety Regulations
1 - GENERAL INFORMATION 1.1 - SAFETY REGULATIONS WARNING - In the event of having to carry out work on the machine while the engine is running, ensure that the work area is well ventilated, where possible using suitable extractor fans. Never leave engines running in closed spaces.
Page 10: Maintenance Regulations
1 - GENERAL INFORMATION 1.2 - MAINTENANCE REGULATIONS - Use genuine DERBI spare parts and lubricants recommended by DERBI. Non-genuine or unauthorised parts may damage the machine. - Only use the specific tools intended for this machine. - During re-assembly, always use new oil seals, gaskets, piston rings and grommets.
Page 11 1 - GENERAL INFORMATION N.B. Replace all seals, retaining rings and O-rings when servicing the engine. All surfaces receiving seals, retaining ring edges and O- rings must be cleaned. Apply oil to all paired parts and bearing during reassembly. Apply grease to the retaining ring edges. After removing them, replace all tab/spacer washers (1) and split pins.
Page 12 1 - GENERAL INFORMATION N.B. Use properly cleaned tools and equipment. See “SPECIAL TOOLS”. CAUTION On dismantling parts, always keep paired items together. This includes gears, cylinders, pistons and other parts submitted to natural wear in pairs. Paired parts must always be reassem- bled or replaced together.
Page 13 1 - GENERAL INFORMATION 1.3 - SPECIAL TOOLS FOR THE ENGINE The following special tools are needed for assembly and for com- plete and exact adjustments. Only use the proper special tools; thereby avoiding damage caused by the use of unsuitable tools or improvised techniques.
Page 14 1 - GENERAL INFORMATION Ref. 865207 Set of tools for 125cc 4-stroke 4v engine. THE SET OF TOOLS FOR THE ENGI- N.B. NE DOES NOT INCLUDE TOOL REF. 866380. Ref. 865259 Camshaft crown wheel locking tool. Ref. 865260 Magneto flywheel locking tool. Ref.
Page 15 1 - GENERAL INFORMATION Ref. 866380 Tool kit (A-B-C) for extracting and fitting water pump oil seal. Ref. 00H05300041 Clutch bell housing locking tool. Ref. 864868 Magneto flywheel extractor tool.
Page 16 1 - GENERAL INFORMATION 1.4 - SPECIAL TOOLS - CHASSIS The following special tools are needed for assembly and for com- plete and exact adjustments. Only use the proper special tools; thereby avoiding damage caused by the use of unsuitable tools or improvised techniques.
Page 17: Technical Data
1 - GENERAL INFORMATION 1.5 - TECHNICAL DATA GENERAL MACHINE DIMENSIONS Distance between wheel shafts 1353 mm Length 1968 mm Wide 720 mm High 810 mm Weight 135 Kg ENGINE Diameter x stroke 58 mm. x 47 mm Cubic capacity 124,2 cm Power 15 HP at 9.250 rpm...
Page 18 1 - GENERAL INFORMATION GENERAL ELECTRICAL SYSTEM Spark plug NGK CR8 EB ÷ Gap between electrodes (plug gap) 0,8 mm Charging system Three-phase magneto Regulated voltage to battery 13v-15v at 8.000 rpm Ignition system Electronic CDI type Battery FTX7L-BS, 12v - 6Ah (MF type) Starting system Electric CAPACITIES AND TYPES OF FLUIDS...
Page 19 1 - GENERAL INFORMATION ENGINE PISTON DIAMETER (D) CAT M 57,953-57,960 mm CAT N 57,960-57,967 mm CAT O 57,967-57,974 mm CAT P 57,974-57,981 mm EXT. DIAMETER MEASUREMENT POINT PISTON (C) 7,5 mm DIAMETER OF PISTON GUDGEON PIN ORIFICE (E) 15,003-15,008 mm DIAMETER OF PISTON GUDGEON PIN (a) Standard 14,997-15,00 mm...
Page 20 1 - GENERAL INFORMATION ENGINE CYLINDER DIAMETER CAT M 58,010-58,017 mm CAT N 58,017-58,024 mm CAT O 58,024-58,031 mm CAT P 58,031-58,038 mm CYLINDER WARP 0,05 mm CYLINDER-PISTON ASSEMBLY 0,050-0,064 mm CYLINDER HEAD WARP SET 0,05 mm ENGINE COMPRESSION VALUE Standard more than 15 kg/cm Minimum...
Page 21 1 - GENERAL INFORMATION ENGINE VALVE DIAMETERS (A) Inlet 21,90 - 22,05 mm Exhaust 18,70 - 18,85 mm “A” WIDTH OF VALVE SEATS (B) Inlet 2,33 - 2,63 mm Exhaust 2,82 - 3,12 mm “B” VALVE STEM DIAMETER Inlet 3,97 - 3,98 mm Exhaust 3,96 - 3,97 mm VALVE GUIDE INTERNAL DIAMETER (A)
Page 22 1 - GENERAL INFORMATION ENGINE VALVE SPRINGS (A) Inlet, free length 33,24 mm Exhaust, free length 33,24 mm Inlet, working length (valve closed) 26 mm Exhaust, working length (valve closed) 26 mm Inlet, work load 101,87-116,13 N (10,19-11,61 Kgf) Exhaust, work load 101,87-116,13 N (10,19-11,61 Kgf) CRANKSHAFT Crankshaft thickness (A)
Page 23 1 - GENERAL INFORMATION FUEL SUPPLY SYSTEM Make KEIHIN Model CVK Ø30 MAIN JET CIRCUIT Main jet Main air jet Atomiser (emulsifier tube) Outer Diameter 5,0 mm Inner Diameter 2,8 mm Tapered needle Make NDYD Diameter 2,490 mm IDLING CIRCUIT Idling jet Minimum air jet Float Height...
Page 24 1 - GENERAL INFORMATION LUBRICATION SYSTEM Oil pressure (manometer connected in sensor) 4,2 Bar Pump with 2 rotors Oil suction rotor Thickness 13,5 mm Oil pumping rotor Thickness 8,5 mm Radial clearance (1) between rotor points 0,04 mm Radial clearance (2) between rotor points 0,08 mm Axial clearance (3) between Rotor 1 and pump body 0,04 mm...
Page 25 1 - GENERAL INFORMATION BRAKES Thickness of front brake disks (standard) 4 mm Service limit for thickness of front brake disks 3,5 mm Thickness of rear brake disks (standard) 3,5 mm Service limit for thickness of rear brake disks 3 mm Brake disk warp 0,2 mm Brake pads service limit...
Page 26: Tightening Torques
1 - GENERAL INFORMATION 1.6 - TIGHTENING TORQUES STANDARD BOLTS AND SCREWS The following table specifies torques for securing devices with ISO standard thread. The torque specifications for special components or assem- blies are indicated in the respective chapters of this manual. To prevent distortions, tighten assemblies with various fixing devices progressively and in a crossed or alternating manner until the specified torque is reached.
Page 27 1 - GENERAL INFORMATION ENGINE TIGHTENING TORQUES TIGHTENING TORQUE THREAD MEA- PARTS TO BE TIGHTENED DESCRIPTION Obs. SUREMENT Kgf.m N·m Spark plug 1,2-1,4 12-14 Bolt 1-1,2 Cylinder head cover 10-12 Bolt Camshaft bridge 1-1,2 10-12 Bolt Timing sprocket 1 2,5-2,7 25-27 Apply thread sealant* Bolt...
Page 28: Engine Tightening Torques
1 - GENERAL INFORMATION ENGINE TIGHTENING TORQUES TIGHTENING TORQUE THREAD MEA- PARTS TO BE TIGHTENED Obs. DESCRIPTION SUREMENT Kgf.m N·m Magneto cover Bolt 1,1-1,3 11-13 Oil sensor cable securing Bolt 0,3-0,5 Neutral sensor indicator M10x1,25 0,8-1,0 8-10 Oil dipstick M12x1,5 0,4-0,6 Magneto stator Bolt...
Page 29: Chassis Tightening Torques
1 - GENERAL INFORMATION CHASSIS TIGHTENING TORQUES TIGHTENING TORQUE THREAD MEA- PARTS TO BE TIGHTENED Obs. DESCRIPTION SUREMENT Kgf.m N·m Bolt M8x125 8.8 1,7-1,9 17-19 Apply thread sealant* Semi-handlebar- plate sec. dev. 3,5-4,5 Counterweight-handlebars sec. dev. Bolt M5x80 8.8 0,35-0,45 Steering lock-forks plate sec.
Page 30 2 - PDI (Pre-delivery inspection) 2 - PDI (Pre-delivery inspection) 2.1 - PDI (Pre-delivery inspection) ........... 31...
Page 31: Pdi (Pre-Delivery Inspection)
2 - PDI (Pre-delivery inspection) Checking the assembly and preparing the machine for delivery to the first purchaser (PDI). PREPARATION UNPACKING - check for damage and missing parts. FRONT AND REAR BRAKES – clean, inspect. ENGINE OIL – Check level. FUEL TANK AND TAP –...
Page 32 Hand over to customer. WARRANTY REGISTRATION CARD – Fill in the necessary information and hand the copy to the customer, then return the original to DERBI immediately. HANDLING – Explain the correct handling of the vehicle.
Page 33 3 - MAINTENANCE 3 - MAINTENANCE 3.1 - LOCATION OF ELEMENTS ............3.2 - REMOVING BODYWORK ELEMENTS ........3.3 - MAINTENANCE TABLE ............3.4 - LUBRICATION POINTS ............3.5 - INSPECTION AND MAINTENANCE ........3.6 - MAINTENANCE PIECES ............
Page 34: Location Of Elements
3 - MAINTENANCE 3.1 - LOCATION OF ELEMENTS Starter relay Battery Air filter CDI ignition unit Instrument panel (remove tank) multi-function button Throttle cable tensioner Regulator-Rectifier Adjusting idling speed Oil filter Radiator drain plug Speed sensor RIGHT-HAND SIDE VIEW...
Page 35 3 - MAINTENANCE Expansion chamber Ignition coil Main Relay and Fuses (remove tank) Horn Engine timing Engine oil Starter motor Engine oil filler plug and inspection drain plug dipstick points LEFT-HAND SIDE VIEW...
Page 36: Removing Bodywork Elements
3 - MAINTENANCE 3.2 - REMOVING BODYWORK ELEMENTS IF THE FITTING PROCEDURE IS N.B. NOT DESCRIBED, IT IS UNDERS- TOOD THAT THE PROCESS IS THE OPPOSITE TO THAT FOR REMO- VAL. SEAT REMOVAL 1. Remove: - Insert the ignition key and turn it anticlockwise a 1/4 of a turn.
Page 37 3 - MAINTENANCE PILLION PASSENGER SEAT REMOVAL 1. Unscrew: - The securing bolt (A), located inside the cowling. 2. Remove: - The seat by pulling it backwards. FITTING 1. Insert: - The seat flange under the bracket. 2. Push: - The seat backwards. 3.
Page 38 3 - MAINTENANCE COWLING TOP COVER REMOVAL 1. First remove: * The seat. * The pillion passenger seat. 2. Unscrew: - The bolt (A) securing the cover at the bottom. 3. Remove: - The cover by pulling it backwards. COWLING REMOVAL 1.
Page 39 3 - MAINTENANCE 4. Remove: - The cowling by pulling it backwards. BOTTOM TANK COVER REMOVAL (same both sides) 1. Unscrew: - The bolt (A) located at the bottom of the front wheel arch. 2. Unscrew: - The bolt (B) located at the top of the front wheel arch. 3.
Page 40 3 - MAINTENANCE BOTTOM FAIRING REMOVAL (same both sides) 1. First remove: * The bottom tank cover. 2. Unscrew: - Remove the 4 side bolts (A) from the bottom fairing. 3. Unscrew: - The 2 bolts (B) located at the bottom of the cover. 4.
Page 41 3 - MAINTENANCE SILENCER END COVER REMOVAL 1. Open: - The clip (A) securing the drain tubes from the tank and the carburettor. 2. Unscrew: - The 2 left-hand bolts on the silencer end cover. 3. Unscrew: - The right-hand bolt (C) on the silencer end cover. 4.
Page 42 3 - MAINTENANCE TOP TANK COVER REMOVAL (same on both sides) 1. First remove: * The seat. 2. Unscrew: - The front bolt on the tank and tilt it backwards. SLOSHING FUEL MAY CAUSE IT WARNING TO FALL FORWARDS. 3. Unscrew: - and remove the 5 bolts (A) from the cover.
Page 43 3 - MAINTENANCE FRONT BUBBLE SCREEN REMOVAL 1. Unscrew: - and remove the 6 bolts from the bubble screen. 2. Remove: - The bubble screen by sliding it upwards. PROTECT THE BUBBLE SCREEN TO CAUTION PREVENT IT FROM BEING DAMA- GED.
Page 44 3 - MAINTENANCE CENTRAL FRONT FAIRING REMOVAL 1. First remove: * The central bubble windscreen. 2. Remove: - The 9 bolts (A) from the instrument panel bracket and remove it. 3. Disconnect: - The instrument panel. 4. Retirar: - The plastic clips holding the cables. 5.
Page 45 3 - MAINTENANCE 9. Disconnect: - The connectors from each light unit. 10. Remove: - The 2 bolts (A) from the rear-view mirror (on each side) and remove them. 11. Remove: - The 2 bolts (B), 1 on each side, securing the front central fairing.
Page 46 3 - MAINTENANCE FUEL TANK PETROL IS EXTREMELY INFLA- WARNING MMABLE CERTAIN CONDITIONS MAY EXPLODE. SMOKING MUST NOT BE ALLO- WED IN THE WORK AREA, NOR SHOULD THERE BE NAKED FLA- MES OR SPARKS. REMOVAL 1. Remove: - The front bolt on the tank and tilt it backwards. THE SLOSHING PETROL MAY MAKE WARNING IT FALL FORWARDS.
Page 47 3 - MAINTENANCE BOTTOM COWLING CLOSING COVER REMOVAL 1. First remove: * The top cowling cover. * The cowling. * The rear mudguard supplement. 2. Unscrew: - The 2 bolts (A) from the cover, gaining access to these through the rear wheel arch. 3.
Page 48 3 - MAINTENANCE 3.3 - PERIODICAL MAINTENANCE TABLE N.B. This chapter contains all the necessary information for carrying out recommended inspections and adjust- ments. If followed, these preventative maintenance procedures will ensure a reliable operation of the ma- chine and a longer operating life. The need for costly servicing will be significantly reduced. This information applies not only to machines already in service but also new machines in preparation for being sold.
Page 49 3 - MAINTENANCE X 1000 km. (odometer) CYCLE WHEELS BRAKE PADS FLEXIBLE BRAKE HOSES BRAKE LEVERS AND THROTTLE TWIST GRIP BRAKE FLUID Change every 2 years or 20,000 kilometres (whichever comes first) FUEL PIPES Check for possible fluid leaks (petrol, oil, coolant, brake fluid) EXHAUST SYSTEM ENGINE MOUNTING BOLTS...
Page 50 3 - MAINTENANCE X 1000 km. (odometer) ELECTRICAL ELECTRIC FAN AND THERMAL SWITCH LIGHTING BATTERY CONTROL ELEMENTS SIGNALLING HORN X 1000 km. (odometer) GENERAL Carry out an on-road test dri- ve, paying attention to the ge- neral operation of the brakes, steering, clutch, suspensions, engine, lighting and instrument panel lights.
Page 51 3 - MAINTENANCE 3.4 - LUBRICATION POINTS Seat lock Throttle cable Front brake lever Ignition switch Footrest Rear brake pedal Clutch cable Mileometer take-off Clutch lever Fuel cap lock Footrest Prop-stand Side bracket Transmission chain...
Page 52: Inspection And Maintenance
3 - MAINTENANCE 3.5 - INSPECTION AND MAINTENANCE 3.5.1 - ADJUSTING THE TIMING CHAIN PLAY 1. Check: - Turn the wheel and find the point where is the least amount of play. THE CORRECT POINT FOR N.B. MEASURING PLAY IS THE HALF WAY POINT (A) BETWEEN THE SPROCKET AND THE CROWN WHEEL.
Page 53 3 - MAINTENANCE TRANSMISSION CHAIN 1. Inspect: - The chain for rigidity. Rigidity => Clean and lubricate or renew. 2. Inspect: - Transmission chain(1). - Rear sprocket (2). - Sprocket. More than ½ tooth of wear => Renew the chain. IT IS RECOMMENDED TO RENEW N.B.
Page 54 3 - MAINTENANCE FITTING A NEW TRANSMISSION KIT (SPROCKET, REAR SPROCKET AND CHAIN). 1. Fit the new: - Crown wheel and sprocket assembly. 2. Fit: - The crown wheel bolts. - The sprocket securing bolts. Crown wheel bolts: 14-15 N.m ( 1,4-1,5 kgf.m)* Sprocket securing bolts: 3,5-4,5 N.m ( 0,35-0,45 kgf.m)* *APPLY LOCTITE 243...
Page 55 3 - MAINTENANCE INSPECTING THE EXHAUST SYSTEM 1. Inspect: - The nuts (1). Loose/damaged => Tighten/renew. - Gasket (exhaust pipe). Leaking exhaust fumes => Tighten/renew. The nuts: 1,7-1,9 N.m (17-19 kgf.m) 2. Inspect: - The clamp (2) joining the exhaust pipe to the silencer. Loose/damaged =>...
Page 56 3 - MAINTENANCE AIR FILTER RENEWAL IF THE MACHINE IS USED IN THE N.B. RAIN OR IN DUSTY AREAS, CHECK AND RENEW THE FILTER MORE FREQUENTLY THAN THE DUE DA- TES INDICATED IN THE USE AND MAINTENANCE MANUAL’S PRO- GRAMMED MAINTENANCE TABLE. REMOVAL 1.
Page 57 3 - MAINTENANCE INSPECTING THE SPARK PLUG 1. Remove: - The spark plug connector. - The spark plug . BEFORE REMOVING THE SPARK PLUG, BLOW THE AREA AROUND THE PLUG CAUTION WITH COMPRESSED AIR TO ELIMINATE ANY DIRT THAT MIGHT FALL INTO THE ENGINE.
Page 58 3 - MAINTENANCE ADJUSTING THE CLUTCH LEVER 1. Check: - Clutch lever play (A). Clearance (clutch lever): 10 - 15mm at the end of the lever. Outside that specified => Adjust. 2. Adjust: - Clutch cable play. Adjustment steps: 1. Loosen: - Turn the locknut (2).
Page 59 3 - MAINTENANCE ADJUSTING THE THROTTLE CABLE BEFORE ADJUSTING N.B. THROTTLE CABLE PLAY, THE TICK-OVER MUST BE ADJUS- TED. 1. Check: - Throttle cable play (1). Outside that specified => Adjust. Clearance: 2÷3 mm. At the throttle twist grip. 2. Adjust: - Throttle cable play.
Page 60 3 - MAINTENANCE ADJUSTING THE GEAR LEVER The height of the gear lever can be adjusted by adjusting the lever backlash. 1. Check: - Gear lever height. Adjustment steps: 1. Unscrew: - The nut (1). 2. Turn: - The adjuster (2) inwards or outwards until the specified play is obtained.
Page 61 3 - MAINTENANCE ADJUSTING THE FRONT BRAKE This machine is fitted with hydraulically activated disk brakes. This type of brakes comes with adjustment factory set. You must check that the brake fluid level is between the maximum and minimum. 1. Check: - The brake lever play (a).
Page 62 3 - MAINTENANCE ADJUSTING THE REAR BRAKE 1. Check: - Brake pedal play (a). - Brake fluid level (b). Outside that specified => Adjust. Play: 3-5 mm 2. Adjust: - Brake pedal play. Adjustment steps: 1. Unscrew: - The nut (1). 2.
Page 63 3 - MAINTENANCE INSPECTING THE FRONT BRAKE PADS 1. Unscrew: - The brake calliper bolts (1). 2. Remove: - The brake calliper. 3. Inspect: - The brake pads (2). 4. Measure: - The brake pad lining thickness. If the lining of either of them is below the service limit =>...
Page 64 3 - MAINTENANCE 5. Fit: - The calliper onto the forks. 6. Tighten: - The brake calliper bolts (4). Bolts tightening torque: 35-40 N.m ( 3,5-4,0 kgf.m)* *APPLY LOCKTITE 243 WARNING TYPE THREAD SEALANT 7. Tighten: - The stud to nominal torque. Stud tightening torque: 12-16 N.m ( 1,2-1,6 kgf.m) 8.
Page 65 3 - MAINTENANCE INSPECTING THE REAR BRAKE PADS REMOVAL 1. Firstly remove: - Rear whel. 2. Unscrew: - The brake calliper bolts (1). 3. Remove: - The brake calliper. 4. Inspect: - The brake pads (2). 5. Measure: - The brake pad lining thickness. If the lining of either of them is below the service limit =>...
Page 66 3 - MAINTENANCE 4. Fit: - The calliper-bracket assembly to the swinging arm. - The rear wheel assembly. 5. Tighten: - The nut (1) to the nominal torque. Nut (1) (rear wheel shaft): 70-80 N.m (7-8 kgf.m) 6. Tighten: - Once the rear wheel shaft nut (1) has been tightened, tighten the tensioning bolts (2).
Page 67 3 - MAINTENANCE INSPECTING THE TYRES 1. Measure: - Tyre pressure Outside that specified => Adjust. TYRE PRESSURES SHOULD ONLY WARNING BE CHECKED OR ADJUSTED WHEN THEIR TEMPERATURE IS THE SAME AS AMBIENT TEMPERATURE. THE TYRE PRESSURE AND SUSPENSION SHOULD BE ADJUSTED IN ACCOR- DANCE WITH THE TOTAL LOAD, RIDER, PILLION PASSENGER AND ACCES- SORIES (COVERS, SIDE-BAGS, ETC.
Page 68 3 - MAINTENANCE INSPECTING THE COOLANT LEVEL. ENSURE THAT THE MOTORCYCLE N.B. IS FULLY UPRIGHT WHEN CHEC- KING THE COOLANT LEVEL. 1. Position: - The motorcycle fully upright on a flat surface. 2. Inspect (cold): - The coolant level, which should be between the maximum and minimum marks.
Page 69 3 - MAINTENANCE CHANGING THE ENGINE OIL 1. First remove: * The bottom fairing (to gain access to the drain plug and the oil filter). 2. Start up: - The engine and leave to warm up for a few minutes. 3.
Page 70 3 - MAINTENANCE INSPECTING THE ENGINE OIL LEVEL ENSURE THAT THE MOTORCYCLE N.B. IS FULLY UPRIGHT WHEN CHEC- KING THE ENGINE OIL LEVEL. 1. Position: - The motorcycle fully upright on a flat surface. 2. Start up: - The engine and leave to warm up for a few minutes. 3.
Page 71 3 - MAINTENANCE ADJUSTING THE VALVE SETTINGS THE VALVE SETTINGS ARE ADJUS- N.B. TED BY MEANS OF SHIMS OR CA- LIBRATED TAPPETS (1). THE SHIMS VARY IN 0.05 MM IN- CREMENTS. THERE ARE 12 AVAILABLE (2.2 MM TO 2.7 MM). THIS TASK SHOULD BE PERFOR- MED WITH THE ENGINE COLD (AMBIENT TEMPERATURE).
Page 72 3 - MAINTENANCE DETAIL SHOWING THE ALIGNMENT OF THE MARK (5) WITH THAT EXISTING ON THE FLYWHEEL (6). UP TO ENGINE NUMBER 7015, N.B. THE MARK (6) (A CIRCLE) DOES NOT EXIST. ON THESE ENGINES (FROM 0001 TO 7015), THE MARK (6) IS A LINE (7) WHICH HAS TO BE ALIGNED WITH THE END OF THE ORIFICE.
Page 73 3 - MAINTENANCE ADJUSTING VALVE SETTINGS THAT ARE OUTSIDE THAT SPECIFIED Outside that specified => Dismantle the timing STEPS TO FOLLOW TO DISMANTLE THE TIMING (continues from Point 3 onwards) 1. Extract: - The starter motor connector. - The 2 bolts (1) securing the starter motor. - The starter motor (2).
Page 74 3 - MAINTENANCE TIE A PIECE OF WIRE TO THE N.B. TIMING CHAIN TO PREVENT IT FROM DROPPING INTO THE ENGINE. 5. Extract: - The 2 locking pins (8). - The 8 bolts (9) from the camshaft bridge (loosen them by following a cross pattern).
Page 75 3 - MAINTENANCE 8. Select: - The valve shim according to the attached table. REFERENCE THICKNESS (mm) CM222701 2,20 CM222702 2,25 CM222703 2,30 CM222704 2,35 THICKNESS CM222705 2,40 CM222706 2,45 CM222707 2,50 CM222708 2,55 CM222709 2,60 CM222710 2,65 CM222711 2,70 CM222712 2,75 A series of 4 and 3 digits will be found stamped onto the inside of the shim.
Page 76 3 - MAINTENANCE POSITION CAMSHAFT N.B. Orifices LOCKING ORIFICES FACING UPWARDS. 11. Fit: - The camshaft bridge (10). - The 8 bolts (9) into the camshaft bridge (tighten them by following a cross pattern). The bolts (camshaft bridge): 1-1,2 kgf.m (10-12 N.m) - The locking pins (8).
Page 77 3 - MAINTENANCE BEFORE FITTING THE TENSIO- CAUTION NER GATHER IT IN COMPLETE- LY IN ORDER TO AVOID DAMA- GE TO THE TIMING CHAIN. 14. Fit: - A NEW tensioner seal. - The timing chain tensioner (17). - The 2 tensioner bolts (4). Timing chain tensioner bolts.
Page 78 3 - MAINTENANCE 20. Fit: - The rocker cover (18). - The 4 rocker cover bolts (19). - The spark plug. (Rocker cover) bolts: 1-1,2 kgf.m (10-12 N.m) MAKE SURE THAT THE ROCKER N.B. COVER GASKET IS PROPERLY POSITIONED AROUND SPARK PLUG HOUSING.
Page 79 3 - MAINTENANCE MEASURING THE COMPRESSION PRESSURE AN INSUFFICIENT COMPRES- N.B. SION PRESSURE WILL LEAD TO A LOSS OF POWER. BEFORE MEASURING COMPRESSION, IT IS IMPOR- TANT TO ENSURE THAT THE VALVE CLEARANCES ARE CO- RRECT. 1. Check: - Valve settings. Outside that specified =>...
Page 80 3 - MAINTENANCE RESETTING SERVICE INDICATOR 1- Once the machine has travelled the distance set out on the table below, the system will activate the inspection function, which appears on the display in the form of the following icon: 2- Service intervals FIRST WARNING 1000 Kms WARNING INTERVAL...
Page 81 3 - MAINTENANCE 5- The code 423 should now be entered. The first figure will change from 0 to 9 one second at a time. When the figure arrives at the desired number (in the case of the example, 4), press MODE to save in memory: 6- The second figure will begin to change (in this case, halt it when it reaches 2): 7- Do the same with the third figure (halt it when it reaches 3):...
Page 82 3 - MAINTENANCE 9- The change from kilometres to miles or vice versa is done by holding down the MODE button for over three seconds. 10- The following function is the one for resetting service/total km. To do so, pressing MODE briefly will display the follo- wing: 11- The icon with the spanner symbol will only appear when a service is overdue.
Page 83 3 - MAINTENANCE 3.6 - MAINTENANCE PIECES FIGURE CODE DESCRIPTION FIGURE CODE DESCRIPTION 866221 RIGHT MIRROR 866692 SET OF BRAKE PADS AIR FILTER FOAM 866222 861130 LEFT MIRROR THROTTLE GRIP 866266 862931 BLANK KEY CYLINDER PISTON 00G00909071 874533 GRIP ASSEMBLY PISTON 00H00904291 CLUTCH LEVER...
Page 84 4 - ENGINE 4 - ENGINE 4.1 - IDENTIFICATION OF SETS ............4.2 - REMOVING THE ENGINE FROM THE FRAME ......4.3 - DISMANTLING THE ENGINE ........... 4.4 - INSPECTING THE ENGINE ELEMENTS ........4.5 - ASSEMBLING THE ENGINE ............4.6 - FITTING THE ENGINE INTO THE FRAME ......
Page 85: Identification Of Sets
4 - ENGINE 4.1 - IDENTIFICATION OF SETS CRANKCASE LOCATION CRANKCASE MECHANISED DIAMETER 1/2 S/T BALANCE SHAFT GEARINGENGRANAJES PRIMARY SHAFT GEARING CRANKCASE MACHINED DIAMETER (mm) (mm) CLASS 1 36.500 36.508 CLASS 2 36.508 36.516 BALANCE SHAFT – GEAR SET CRANKSHAFT GEAR CRANKSHAFT GEAR REFERENCE REFERENCE...
Page 86 4 - ENGINE PRIMARY SHAFT - GEAR SET ENGRANAJE CIGÜEÑAL ENGRANAJE EJE PRI. (CAMPANA EMBRAGUE) REFERENCE REFERENCE 8714475001 8714605001 X CLASS Y CLASS 8714475002 8714605002 N.B.: The crankcases available as spare parts are always of the X kind. (mm) (mm) X CLASS 86.00 86.04...
Page 87 4 - ENGINE HALF-BEARING CRANKCASE MACHINED DIAMETER (D1) (mm) (mm) CLASS 1 36.500 36.508 CLASS 2 36.508 36.516 CRANKSHAFT DIAMETER MIN (mm) MAX (mm) REFERENCE CLASS 1 32.480 32.485 8711475001 CLASS 2 32.485 32.490 8711475002 HALF-BEARING THICKNESS MIN (mm) MAX (mm) Ref.
Page 88 4 - ENGINE VALVE GUIDES REFERENCE THICKNESS (mm) CM222701 2,20 CM222702 2,25 CM222703 2,30 CM222704 2,35 CM222705 2,40 CM222706 2,45 CM222707 2,50 CM222708 2,55 THICKNESS CM222709 2,60 CM222710 2,65 CM222711 2,70 CM222712 2,75 A series of 4 and 3 digits will be found stamped onto the inside of the shim. N.B.
Page 89: Removing The Engine From The Frame
4 - ENGINE 4.2 - REMOVING THE ENGINE FROM THE FRAME DO NOT REMOVE THE EXHAUST WARNING SYSTEM OR THE RADIATOR HO- SES IF THE ENGINE IS HOT, SINCE THIS COULD RESULT IN BURNS. REMOVAL 1. Firstly remove: * The bottom side covers. * The bottom fairing.
Page 90 4 - ENGINE 8. Disconnect: - The pipe (7) from the radiator to the water pump. 9. Disconnect: - The carburettor clamps (8) and extract it. - Electrical connections (starter motor, magneto cover, etc.). 10. Remove. - The 2 top securing bolts (9). - The 2 bottom securing bolts (10).
Page 91 4 - ENGINE 4.3 - DISMANTLING THE ENGINE 1. Remove: - The inspection plugs (1) in the flywheel cover. 2. Remove: - The spark plug (2). 3. Remove: - The 4 rocker cover bolts (3). - The rocker cover (4). 4.
Page 92 4 - ENGINE DETAIL SHOWING THE ALIGNMENT OF THE MARK (5) WITH THAT EXISTING ON THE FLYWHEEL (6). UP TO ENGINE NUMBER 7015, N.B. THE MARK (6) (A CIRCLE) DOES NOT EXIST. ON THESE ENGINES (FROM 0001 TO 7015), THE MARK (6) IS A LINE (7) WHICH HAS TO BE ALIGNED WITH THE END OF THE ORIFICE.
Page 93 4 - ENGINE 7. Remove: - The starter motor connector - The 2 bolts (10) securing the starter motor. - The starter motor (11). REMOVE THE STARTER MOTOR N.B. TO ENABLE EASY EXTRACTION OF THE TIMING CHAIN TEN- SIONER . 8.
Page 94 4 - ENGINE TIE A PIECE OF WIRE TO THE N.B. TIMING CHAIN TO PREVENT IT FROM DROPPING INTO THE ENGINE. 11. Remove: - The 2 locking pins (17). - The 8 bolts (18) from the camshaft bridge (loosen them by following a cross pattern).
Page 95 4 - ENGINE 14. Fit: - The tool for supporting the piston (30). Tool for supporting the piston. Ref. 865261 BEFORE REMOVING CIRCLIP FROM THE GUDGEON N.B. PIN, COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PREVENT OBJECTS FROM FA- LLING INTO THE ENGINE.
Page 96 4 - ENGINE 17. Remove: - The 3 bolts (34) from the water pump cover (35). THERE IS NO NEED TO REMO- N.B. VE THE WATER PUMP COVER, BUT IT IS RECOMMENDED TO DO SO AS THIS AIDS IN FIT- TING THE CLUTCH COVER.
Page 97 4 - ENGINE 20. Remove: - The 5 bolts (41) with washer and spring from the clutch closing cover. - The clutch closing cover (42). 21. Remove: - The driving disks (43) and driven disks. 22. Abrir: - The seal tab (44). 23.
Page 98 4 - ENGINE 26. Remove: - The circlip and washer (49) from the pump driving gear (50). - The pump driving gear (50). 27. Remove: - The 3 oil pump bolts (51). - The oil pump (52). 28. Remove: - The oil pump gasket (7). (Renew on refitting). 29.
Page 99 4 - ENGINE 30. Remove: - The gear change spring bolt (56). - The gear lever (57). - The lubrication circuit by-pass valve (V). 31. Fit: - The balance shaft locking tool (58). Balance shaft locking tool: Ref. 864486 32. Remove: - The nut balance shaft nut (59).
Page 100 4 - ENGINE 36. Remove: - The timing chain gear (65). - The timing chain (66) from the top. - The intermediate balance shaft gear (67). TAP THE ALLEN KEY WITH A N.B. NYLON MALLET TO UNLOCK IT (BOLT 68). 37.
Page 101 4 - ENGINE 41. Fit: - The magneto flywheel extractor (75). Magneto flywheel extractor tool: Ref. 864868 42. Remove: - The magneto flywheel. - The magneto flywheel extractor. 43. Remove: - The starter crown wheel retaining plate (76). - The 2 starter system sprockets (77). 44.
Page 102 4 - ENGINE 45. Remove: - The left-hand crankcase (83) upwards. TO AID THE TASK, SET THE EN- N.B. GINE DOWN ON A WOODEN BOX. 46. Remove: - The gasket from the crankcases (84). 47. Remove: - The 2 gear selector fork shafts. Long shaft (85).
Page 103 4 - ENGINE 49. Remove: - The secondary shaft (89). - The primary shaft (90). TOTAL LENGTH OF SECONDARY N.B. SHAFT 92’2 mm (+010 - 0,18 mm).
Page 104 4 - ENGINE 4.4 - INSPECTING THE ENGINE ELEMENTS CYLINDER HEAD CHECKING FOR TIGHT VALVE SEATING - Test both the inlet and the exhaust valves. - The test should be carried out by filling the manifold with petrol and checking that petrol does not ooze excessively past the valves.
Page 105 4 - ENGINE - From each of the valves: - Extract the 2 semi-cones. - Release the springs. - Remove the plates and the springs. - Extract the valves. MAKE A NOTE OF THE PO- N.B. SITION OF THE VALVES FOR THEIR SUBSEQUENT REFIT-...
Page 106 4 - ENGINE VALVE GRINDING 1. Eliminate: - Carbon sediments (of the surface of the valve seat). 2. Inspeccione: - Valve seats. Grooves/wear => Grind the valve. - Apply blue mechanical dye (Prussian blue) to the valve face. - Fit the valve into the cylinder head. - Press the valve against the guide and against the seat to make a visible mark.
Page 107 4 - ENGINE Steps for seating valves: - Apply a fine abrasive paste (grinding paste) to the valve seat. DO NOT ALLOW THE PASTE TO CAUTION PENETRATE IN THE SPACE BET- WEEN THE VALVE STEM AND THE VALVE GUIDE. - Apply acid with molybdenum disulphate to the valve stem. - Fit the valve into the cylinder head.
Page 108 4 - ENGINE VALVES HAVE BEEN CAUTION GROUND, WHEN THE CYLINDER HEAD IS REFITTED ONTO THE ENGINE, ADJUST THE VALVE SET- TINGS. CULATA 1. Eliminate: - Carbon sediments (from the combustion chamber) Use a rounded spatula. AVOID USING ANY SHARP EDGED N.B.
Page 109 4 - ENGINE VALVES, VALVE GUIDES AND VALVE SPRINGS Standard values VALVE DIAMETERS (A) Inlet: 21,90 - 22,05 mm Exhaust : 18,70 - 18,85 mm “A” VALVE STEM DIAMETER Inlet: 3,97 - 3,98mm Exhaust: 3,96 - 3,97mm VALVE GUIDE INTERNAL DIAMETER (A) Inlet: 3,97 - 3,98 mm Exhaust:...
Page 110 4 - ENGINE VALVE SPRINGS (a) Inlet, free length: 33,24 mm Exhaust, free length: 33,24 mm Inlet, working length (valve closed): 26 mm Exhaust, working length (valve closed): 26 mm Inlet, work load: 101,87-116,13 N (10,19-11,61 Kgf) Exhaust, work load: 101,87-116,13 N (10,19-11,61 Kgf) - Spring contact face.
Page 111 4 - ENGINE TIMING CHAIN, SPROCKETS AND ROLLERS Check the condition of the chain, control sprockets and ro- llers. THE CONDITION OF THE TIMING N.B. CHAIN TENSIONER CAN HELP TO INDICATE WHETHER THE CHAIN IS OUT OF SERVICE. 1. Inspect: - Timing chain.
Page 112 4 - ENGINE DIÁMETRO CILINDRO (standard values) CAT M: 58,010-58,017mm CAT N: 58,017-58,024 mm CAT O: 58,024-58,031mm CAT P: 58,031-58,038 mm CYLINDER BASE WARP: 0.05 MM Incorrect warp => Renew. PISTON DIAMETER (D) CAT M: 57,953-57,960 mm CAT N: 57,960-57,967 mm CAT O: 57,967-57,974 mm CAT P:...
Page 113 4 - ENGINE DIAMETER OF PISTON GUDGEON PIN (a) Standard 14,997-15,00 mm Service limit 14,995 mm Outside that specified => Renew. PISTON RING TYPE 1st compression ring Cónico Type 1 x 2,5 mm Dimension (BxT) 2nd compression ring Cónico Type 1,2 x 2,5 mm Dimension (BxT) 3rd oil scraper ring...
Page 114 4 - ENGINE CRANKSHAFT (standard values) Crankshaft thickness (A) 46,87-47,05 mm Diameter of crankshaft supports CLASS 1 32,480-32,485 mm CLASS 2 32,485-32,490 mm Crankshaft warp between points (C) 0,1 mm Crankshaft warp at the supports (D) 0,01 mm Axial play of crankshaft in the crankcase 0,15 - 0,43 mm CONNECTING ROD Connecting rod side play (B)
Page 115 4 - ENGINE INSPECTING THE CLUTCH BELL HOUSING 1. Inspect: - Primary sprocket teeth (1). - Clutch housing splines (2). Wear/damage => Renew both sprockets. Excessive noise when functioning => Renew both spro- ckets. - Claws (of the bell housing) (1). Rough edges/wear/damage =>...
Page 116 4 - ENGINE Roll the guide bar on a flat surface. Warping => Renew. DO NOT TRY AND STRAIGHTEN CAUTION A WARPED BAR. 4. Check: - Movement of the gear change forks (in the guide bar) Uneven movement => Renew the fork and the bar. IF THE GEAR CHANGE FORK N.B.
Page 117 4 - ENGINE GEAR TRANSMISSION RATIO N.B. TR = 73/24 = 33/11 = 30/15 = 27/18 = 24/20 = 27/25 = 22/23 7. Inspect: - Gear change shaft (1). Damage/warping/wear => Renew. - Return spring (gear change shaft) (2). - Return spring (limiter rod) (3). Wear/damage =>...
Page 118 4 - ENGINE INSPECTING THE OIL PASSAGES (RIGHT HAND SIDE CASING COVER) 1. Inspect: - Oil passage Obstructions => Blow through with compressed air. CASING 1. Wash the casings well with petrol. 2. Clean the seal-bearing surfaces and the casing contact surfaces well.
Page 119: Assembling The Engine
4 - ENGINE 4.5 - ASSEMBLING THE ENGINE DRIVE SHAFT SPARE PARTS Distributor drum Gear change greasing tube Roller O-ring Washer Z14 gear change output gear Primary fork shaft Output gear seal Cat. 1 gear change fork. 5M80x10 Allen bolt Secondary fork shaft Int.
Page 120 4 - ENGINE ASSEMBLING THE ENGINE 1. Fit: - The secondary shaft (1). - The primary shaft (2). 2. Fit: - The gear selector drum (3). 3. Fit: - The 2 gear selector fork shafts. Long shaft (4). Short shaft (5). - The 3 gear selector forks (6).
Page 121 4 - ENGINE CRANKSHAFT PARTS Crankcases assy. M5x14 bolt Counterweight bearing Top mounting blue semi-bearing Crankcase gasket Bottom mounting blue semi-bearing Crankshaft oil seal Secondary shaft bearing Primary shaft needle bearing assy. Neutral switch Gasket Counterweight shaft needle bearing assy. Bolt M6x75 hex.
Page 122 4 - ENGINE 5. Fit: - The engine crankcase gasket (8) (new gasket). TO AID THE TASK, REST THE N.B. ENGINE ON A WOODEN BOX. 6. Fit: - The left-hand crankcase (9) onto the right-hand crankcase (10), being guided by the centring studs (11). MAKE SURE THAT THE GASKET WARNING REMAINS IN THE CORRECT...
Page 123 4 - ENGINE MAGNETO PARTS Magneto side cover Starter crown wheel retaining plate Magneto cover-crankcase gasket M6x14 bolt O-ring Ignition cover 6M100 hexagonal nut with clamp M6x35 bolt O-ring Oil dipstick Flat washer Stator M 5x25 bolt M 5x16 bolt Bolt Washer Rotor...
Page 124 4 - ENGINE 8. Fit: - The balance shaft (16). 9. Fit: - The 2 starter system sprockets (17). - The starter crown wheel retaining plate (18). - Bolt (19) retaining plate. - The magneto flywheel key (20). Bolt (18): 0,5-0,6 kgf.m (5-6 N.m) 10.
Page 125 4 - ENGINE 12. Fixing: - The rotor onto the magneto flywheel, using the magne- to fl ywheel locking tool (24). Magneto flywheel locking tool: Ref. 865259 Magneto flywheel rotor nut: 8,3-9,0 kgf.m (83-90 N.m) 13. Fit: - The cover gasket (25) (new gasket). 14.
Page 126 4 - ENGINE GEAR CHANGE SELECTOR PARTS Clutch push rod Selector spring stud Clutch lever Bolt Clutch cable securing plate Gear selection lever Selector shaft assembly Spring D12 safety ring Washer Bolt Washer Drum control head Gear selection spring Special bolt Gear lever assy.
Page 127 4 - ENGINE 16. Fit: - Gear change shaft assembly (28). - The bolt (29) on the gear selector distributor. Gear selector distributor bolt: 0,5-0,6 kgf.m (5-6 N.m) 17. Fit: - The gear selector lever (30) and the spring, using the bolt (31).
Page 128 4 - ENGINE OIL PUMP ASSEMBLY PARTS Rubber ring. Flat washer Intermediate oil pump gear Bolt Circlip Oil pump gear Oil pump gear Crankcase / oil pump gasket Oil pressure valve spring Oil by-pass valve Oil filter Oil filter gasket Plug gasket Oil filter plug...
Page 129 4 - ENGINE 19. Fit: - The oil pump gasket (34) (new gasket). 20. Fit: - The oil pump (35). - The 3 oil pump bolts (36). The oil pump bolts: 0,5-0,6 kgf.m (5-6 N.m) ONCE THE PUMP BOLTS HAVE N.B.
Page 130 4 - ENGINE CRANKSHAFT PARTS Crankshaft-connecting rod assy. Counterweight shaft Intermediate gear counterweight Counterweight gear...
Page 131 4 - ENGINE 22. Fit: - The balance shaft gear (39). - The intermediate balance shaft gear (40). ALIGN THE CRANKSHAFT AND CAUTION BALANCER GEARS USING THE GUIDE POINTS. 23. Fije: - The balance shaft locking tool (41). Balance shaft locking tool: Ref.
Page 132 4 - ENGINE 27. Fit: - The fixed timing cWhain roller (45). Fixed timing bolt: 1,0-1,2 kgf.m (10-12 N.m) 28. Fit: - The crankshaft gear (46). - The fitting tool (47). Crankshaft sprocket locking tool: Ref. 864487 29. Fit: -The crankshaft gear nut (48). Crankshaft gear nut: 7,5-8,3 kgf.m (75-83 N.m) 30.
Page 133 4 - ENGINE CLUTCH BELL HOUSING PARTS Clutch bell housing Clutch casing Driving disk (5u.) Driven disk (4u.) Clutch closing cover Clutch spring Bolt with washer Washer M6 hexagonal nut Clutch bolt Separator Washer Nut with tapered spring Engine gear Seeger ring Washer Needle bearing assy.
Page 134 4 - ENGINE 33. Fit: - The clutch bell housing (51) with the central bush. - The separating washer (52). 34. Fit: - The clutch bell housing (52). - The seal (53). - The nut (54). - The tool for fitting the clutch bell housing (55) onto the clutch housing (52).
Page 135 4 - ENGINE 38. Fit: - The driving disks (56) and the driven disks (57). FIT THE DRIVING DISKS (BLA- N.B. DES TO THE RIGHT) AND THE DRIVEN DISKS (ROUNDED PROFILE INWARDS) ALTERNA- TELY ONTO THE CLUTCH HUB, BEGINNING WITH A DRIVING DISK AND ENDING WITH A DRIVING DISK AS WELL.
Page 136 4 - ENGINE CLUTCH COVER PARTS Clutch cover assy. Clutch cover – crankcase gasket Oil filter cover O-ring Oil filter cartridge spring Oil filter cartridge M5x14 bolt Water pump cover O-ring Complete drive shaft Water pump oil seal Clamp M6x35 bolt Oil seal Pump-cylinder head pipe Oil pressure sensor...
Page 137 4 - ENGINE 43. Fit: - The oil filter (64). - The spring (65). - The oil filter plug (66). The oil filter plug: 2,4-2,6 kgf.m (24-26 N.m) 44. Fit: - The water pump cover (67) and the 3 bolts (68). - The coolant pipe (69).
Page 138 4 - ENGINE CYLINDER HEAD AND CYLINDER PARTS Piston-cylinder assy. 1st cat. piston assy. Cylinder – cylinder head gasket Cylinder - crankshaft gasket First piston ring Scraper ring Piston gudgeon pin Piston gudgeon pin circlip Chain tensioner Gasket M6x16 bolt...
Page 139 4 - ENGINE 46. Fit the rings onto the piston in the following order: - Bottom ring (oil ring) (71). - Central ring (scraper) (72). - Top ring (compression) (73). FIT THE RINGS IN SUCH A WAY N.B. THAT THE MANUFACTURER’S MARK IS TOWARDS THE TOP.
Page 140 4 - ENGINE 51. Fit: - The piston gudgeon pin securing circlips (77). DO NOT RE-USE THE PISTON CAUTION GUDGEON CIRCLIPS. ALWAYS FIT NEW ONES. 52. Fit: - The cylinder bottom gasket (78) (new gasket). 53. Lubricate: - The internal surface of the cylinder with engine oil. 54.
Page 141 4 - ENGINE CALCULATING THE BOTTOM GASKET THICKNESS THE CYLINDER GASKET THIC- N.B. KNESS MUST BE CALCULATED TO ESTABLISH THE APPROPRIATE COMPRESSION RATIO. PERFORM CALCULATION WITH THE COMPARATOR GAUGE WITHOUT FITTING ANY CYLIN- DER BOTTOM GASKET. 1. Fit: - The comparer (1) onto the TDC measuring tool (2). PLACE THE COMPARER ON A N.B.
Page 142 4 - ENGINE VALVES AND CAMSHAFT PARTS Cylinder head assy. Gasket 12x13 centring bush Chain guide fixed roller M8x20x1 bolt Chain tensioner mobile roller 8x13 centring bush M6 bolt M8x166 bolt Timing chain 8.5x16x1.5 washer Crown wheel M6x130 bolt 8.25x23x4 washer Distribution gear 125cc exhaust valve 125cc inlet valve...
Page 143 4 - ENGINE (CONTINUES FROM POINT 55) 56. Fit: - The front timing chain roller (81). - The cylinder head gasket (82) (new gasket). - The coolant pipe (83). REMEMBER TO FIT THE FRONT N.B. CHAIN ROLLER BEFORE FIT- TING THE CYLINDER HEAD. 57.
Page 144 4 - ENGINE 59. Fit: - A little engine oil to the camshaft supports. - The camshafts onto their housings: - The inlet camshaft (88). - The exhaust camshaft (89). THE INLET CAMSHAFT BEARS N.B. THE INSCRIPTION “A” EXHAUST CAMSHAFT BEARS THE INSCRIPTION “S”...
Page 145 4 - ENGINE DETAIL SHOWING THE ALIGNMENT OF THE MARK (94) WITH THAT EXISTING ON THE FLYWHEEL (95). UP TO ENGINE NUMBER 7015, N.B. THE MARK (95) (A CIRCLE) DOES NOT EXIST. ON THESE ENGINES (FROM 0001 TO 7015), THE MARK (95) IS A LINE (96) WHICH HAS TO BE ALIGNED WITH THE END OF THE ORIFICE.
Page 146 4 - ENGINE 63. Adjusting the tensioner: - Press the tab (100). - Push the timing chain tensioner (101). - Release the tab (100). DO NOT TIGHTEN THE SPRO- CAUTION CKETS TO THEIR TORQUE SET- TING UNTIL THE SUBSEQUENT TENSIONING OF THE TIMING CHAIN HAS BEEN PERFOR- MED.
Page 147 4 - ENGINE 68. Remove: - The locking pins (93). 69. Check: - The correct functioning of the timing by turning the cranks- haft a number of times. TURN THE CRANKSHAFT IN AN CAUTION ANTICLOCKWISE DIRECTION. ATTEMPTING TO TURN IT IN THE OPPOSITE DIRECTION MAY CAU- SE SERIOUS DAMAGE TO THE EN- GINE.
Page 148 4 - ENGINE 72. Fit: - The starter motor (108). - The 2 bolts (109) securing the starter motor. APPLY LOCTITE 243-TYPE N.B. THREAD SEALANT TO THE 2 BOLTS BEFORE FITTING THEM. Starter motor bolts: 1,1-1,3 kgf.m (11-13 N.m) 73. Fit: - The inlet manifold, using the 3 boltS (110).
Page 149 4 - ENGINE THERMOSTAT PARTS Hose joining the carburet. to the inlet manifold Bolt Intake connector O-ring Thermistor Thermostat Thermostat cover 6.3x8x6.8 bush M6x20 bolt Studs Carburettor clamp...
Page 150: Fitting The Engine Into The Frame
4 - ENGINE 4.6 - FITTING THE ENGINE INTO THE FRAME IT IS ADVISABLE TO PLACE A N.B. SUPPORT UNDER THE ENGINE BEFORE FITTING IT ONTO THE CHASSIS, TO AID THE PRO- CESS. ON REFITTING THE ENGINE, IF NECESSARY USE TOOL CODE NO.
Page 151 4 - ENGINE 5. Fit: - The coolant temperature sensor (6). - The AIS valve (7). - The pipe from the radiator to the thermostat (8). 6. Fit: - The clutch cable (9). - The oil pressure sensor cable (10). 7.
Page 152 4 - ENGINE 9. Fit: - The exhaust pipe. FIT A NEW EXHAUST PIPE- CYLIN- N.B. DER HEAD GASKET. Securing the exhaust pipe to the cylinder head 1,7-1,9 kgf.m (17-19 N.m) 10. Fit: - The chain. CHECK TRANSMISSION N.B. CHAIN ADJUSTMENT. ENSURE THAT THE OIL LEVEL IN CAUTION THE ENGINE IS CORRECT BEFORE...
Page 153 5 - FUEL SUPPLY SYSTEM 5 - FUEL SUPPLY SYSTEM 5.1 - DISMANTLING THE CARBURETTOR ......... 5.2 - ASSEMBLING THE CARBURETTOR ..........5.3 - CHECKING THE FLOAT CHAMBER LEVEL ......5.4 - CHECKING THE VACUUM VALVE AND TAPERED NEEDLE ... 5.6 - CHECKING THE AUTOMATIC CHOKE ........
Page 154 5 - FUEL SUPPLY SYSTEM Carburetor Cover Clamp Spring Bushing Needle Valve Jet min Needle jet Main jet Main jet Float Float bowl seet Kit acceleration pump kit Cover Starter device Plate Starter Carburetor gasket Raccord Tube Tube Tube Clamp Clamp...
Page 155: Dismantling The Carburettor
5 - FUEL SUPPLY SYSTEM 5.1 - DISMANTLING THE CARBURETTOR - To dismantle the carburettor from the engine, move the air filter clear and remove the throttle control cable, the au- tomatic choke connection, the carburettor retaining clamps and the filter box and suction collector, the air feed pipe to the membrane and the inlet connector.
Page 156 5 - FUEL SUPPLY SYSTEM - Remove the clamp and the hood with the ventilation filter from the membrane chamber. - Remove the 4 securing screws and the vacuum chamber cover. WHILE REMOVING THE COVER, WARNING TAKE SPECIAL CARE TO PREVENT THE SPRING FROM SUDDENLY FLYING OUT.
Page 157 5 - FUEL SUPPLY SYSTEM Unscrew the bayonet fitting 1/8th of a turn and extract it, then remove the spring and the valve needle. - Remove the 4 screws indicated in the figure. - Remove the complete bowl with the throttle pump, control and gasket.
Page 158 5 - FUEL SUPPLY SYSTEM - Hold the carburettor suitably and with a punch and ham- mer tap out the float rod, tapping from the throttle control side. - Remove the float (1) and needle (2). - Remove the main jet. - Remove the jet.
Page 159 5 - FUEL SUPPLY SYSTEM - Remove the slow jet. (4). - Remove the screw for adjusting the slow jet flow (pilot jet screw) together with the O-ring, washer and spring. DO NOT ATTEMPT TO DIS- CAUTION MANTLE THE COMPONENTS FITTED INTO CARBU-...
Page 160: Assembling The Carburettor
5 - FUEL SUPPLY SYSTEM 5.2 - ASSEMBLING THE CARBURETTOR - Before proceeding with the assembly, wash the carburettor body carefully with petrol and blow with compressed air. - Pay special attention in the duct supplying fuel to the nee- dle seat (5).
Page 161 5 - FUEL SUPPLY SYSTEM - Check that the butterfly valve and shaft have no unusual wear. - Check that the needle seat (5) has no unusual wear. - If any irregularities are found, renew the carburettor. - Check that the pump rocker arm return spring is not distor- ted.
Page 162 5 - FUEL SUPPLY SYSTEM - Check that the tapered needle of the float has no signs of wear on the sealing surface (8), on the shock absorbing rod and the return spring. - If wear is detected, renew the tapered needle of the float. -Check that the float has no signs of wear on the rod seat, on the plate contacting with the needle, or fuel infiltration.
Page 163 5 - FUEL SUPPLY SYSTEM - Check for leaks at the screw by pouring small amounts of fuel into the chamber. - Fit a new gasket on the bowl. ALWAYS FIT A NEW GASKET TO N.B. ENSURE THERE ARE NO LEAKS. - Fit the bowl onto the carburettor body and tighten the 4 screws.
Page 164: Checking Level Of The Float Chamber
5 - FUEL SUPPLY SYSTEM 5.3 - CHECKING LEVEL OF THE FLOAT CHAMBER - Fit the carburettor tilted as in the figure. - Check that the reference mark on the float is parallel with the flat joining surface of the bowl. - If other positions are detected, modify the positioning of the metal needle control plate until the indicated position is obtained.
Page 165 5 - FUEL SUPPLY SYSTEM - Refit the needle spring. - Refit the vacuum chamber cover, taking care to ensure that the spring is correctly fitted into the housing in this cover. TAKE CARE WHEN FITTING THE CAUTION COVER TO AVOID PINCHING THE MEMBRANE.
Page 166: Checking The Automatic Choke
5 - FUEL SUPPLY SYSTEM 5.5 - CHECKING THE AUTOMATIC CHOKE - Check that the automatic choke piston is not scratched or corroded. - Check that the piston slides freely. - Check that the piston sealing gasket is not distorted. - The choke will be on for more or less time, depending on the atmospheric temperature.
Page 167 5 - FUEL SUPPLY SYSTEM - Continue with the fitting of the choke in the carburettor, pa- ying attention to the correct positioning of the O-ring, insert the plate with the moulded part resting against the choke, and tighten the securing bolt (10). - Position the choke as shown in the figure.
Page 168 6 - COOLING SYSTEM 6 - COOLING SYSTEM 6.1 - DIAGRAM OF THE SYSTEM ............6.2 - DESCRIPTION OF THE SYSTEM AND CHECKING OF ELEMENTS ................6.3 - RENEWING THE WATER PUMP OIL SEAL .......
Page 169: Diagram Of The System
6 - COOLING SYSTEM 6.1 - DIAGRAM OF THE SYSTEM...
Page 170 6 - COOLING SYSTEM...
Page 171 6 - COOLING SYSTEM 6.2 - DESCRIPTION OF THE SYSTEM AND CHECKING OF ELEMENTS DESCRIPTION - There is a small by-pass (1) to heat up the carburettor. - The radiator is fitted with an electric fan. - Activation of the electric fan is controlled by a thermal switch.
Page 172 6 - COOLING SYSTEM - Draining the circuit: Through the water pump inlet pipe. CHECKING THE ELEMENTS - Thermostat. Remove: - The 2 thermostat cover bolts (1). - The thermostat (2). DO NOT REMOVE THE THERMOS- WARNING TAT IF THE ENGINE IS HOT. THERMOSTAT COVER BOLTS TIG- N.B.
Page 173 6 - COOLING SYSTEM CHECKING THE ELEMENTS - Thermostat (checking opening). - Submerge the thermostat in a container filled with coolant. - Submerge a thermometer in the same container, gradua- ted between 0° - 150° C (32° - 302° F). - Position the container over a burner and heat the liquid up slowly.
Page 174 6 - COOLING SYSTEM CHECKING THE ELEMENTS - Temperature sensor (NTC). - Remove the temperature sensor (2) from the cylinder head. - As indicated in the figure, connect a pocket meter (10) (configured to measure resistance) to the temperature sensor (2). - Submerge the temperature sensor in a container 11) filled with oil.
Page 175: Renewing The Water Pump Oil Seal
6 - COOLING SYSTEM 6.3 - RENEWING THE WATER PUMP OIL SEAL DESCRIPTION - The water pump oil seal (1) is of a metal type with a ceramic interior. - If liquid is leaking out of the hole (2) in the clutch cover at the height of the water pump, this is an indication that the oil seal needs to be replaced.
Page 176 6 - COOLING SYSTEM Ref. 866380 N.B. Tool kit (A-B-C) for extrac- ting and fitting water pump oil seal. STEPS FOR REMOVING THE WATER PUMP: - Remove the clutch cover. - Remove the water pump cover and the turbines (right- hand threads).
Page 177 6 - COOLING SYSTEM - Position the gear in the oil seal and push the shaft with B until it is fully in. - Fit the water seal with C. This tool adjusts the seals inter- nal spring preload. - Assemble the remaining elements. DO NOT USE GREASE FOR CAUTION THE PUMP COVER O-RING.
Page 178 7 - LUBRICATION SYSTEM 7 - LUBRICATION SYSTEM 7.1 - DIAGRAM OF THE SYSTEM ............7.2 - DESCRIPCION OF THE LUBRICATION SYSTEM ......
Page 179 7 - LUBRICATION SYSTEM 7.1 - DIAGRAM OF THE SYSTEM...
Page 180 7 - LUBRICATION SYSTEM...
Page 181: Lubrication System
7 - LUBRICATION SYSTEM 7.2 - DESCRIPCION OF THE LUBRICATION SYSTEM DESCRIPTION - Lubrication is the semi-wet crankcase type. - The oil is not contained in the front part of the crank- case (1). - The gearbox (2) is used as an oil tank. - The pump (3) is driven by the clutch via an intermedia- te gearing (4).
Page 182 7 - LUBRICATION SYSTEM Oil passages Right-hand semi-crankcase To bottom of cylinder Clutch cover Oil to filter By-pass Cylinder Oil input to filter Aceite hacia apoyos To bottom of cylinder Sube para árboles de levas Entrada de aceite Crankcases Oil to supports Oil to the piston Right-hand semi-crankcase Rises for...
Page 183 7 - LUBRICATION SYSTEM - The maximum pressure is 4.2 bars, and at the top of the engine the pressure is 1 bar. TO CHECK THE PRESSURE, N.B. CONNECT MANOMETER INSTEAD OF THE SENSOR. - The elements of the circuit are: - Pre-filter (1).
Page 184 8 - CHASSIS 8 - CHASSIS 8.1 - INSPECTING THE WHEELS ............8.2 - FRONT WHEEL ................8.3 - FRONT SUSPENSION ..............8.4 - STEERING ..................8.5 - REAR WHEEL ................. 8.6 - REAR SUSPENSION ..............
Page 185: Inspecting The Wheels
8 - CHASSIS 8.1 - INSPECTING THE WHEELS BALANCE THE WHEEL WHENEVER N.B. A TYRE OR WHEEL HAS BEEN FIT- TED OR REPLACED. NEVER TRY TO CARRY OUT RE- WARNING PAIRS TO A WHEEL RIM. 1. Inspect: - The wheel shaft. (Rolling it on a flat surface).
Page 186 8 - CHASSIS 4. Check: - Front wheel bearings. Bearings allow play in the wheel hub or the wheel does not turn freely => Renew. - Retaining rings. Damaged/worn => Renew 5. Inspect: - The spacer. With scratches/worn => Renew the spacer and the retai- ning ring.
Page 187: Front Wheel
8 - CHASSIS 8.2 - FRONT WHEEL ENSURE THAT THE MOTOR- WARNING CYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. PUT THE MOTORCYCLE ON A FLAT SURFACE. IF THE BRAKE LEVER/PEDAL IS CAUTION APPLIED WITHOUT THE WHEEL BEING FITTED, THE CORRESPON- DING SYSTEM WILL HAVE TO BE BLED.
Page 188 8 - CHASSIS FITTING THE FRONT WHEEL Take note of the following points: 1. Lubricate: - Wheel shaft. - Rodamientos. - Retenes. Recommended lubricant: Lithium soap based grease. 2. Fit: - The front wheel. - Front wheel shaft. 3. Tighten: - The shaft nut.
Page 189: Front Suspension
8 - CHASSIS 8.3 - FRONT SUSPENSION THE LEFT-HAND BAR HAS A N.B. SUSPENSION SPRING INSIDE. THE RIGHT-HAND BAR ONLY ACTS AS A HYDRAULIC DAM- PER (IT HAS NO SPRING). REMOVAL 1. Firstly remove: * The front wheel. LOOSEN THE TOP LOCKING BOLT N.B.
Page 190 8 - CHASSIS 5. Separate: - The bar firmly from the fork stem. 6. Extract: - The dust-guard. 7. Extract: - The safety circlip. 8. Extract: - The oil seal. PLACE A PROTECTOR BETWEEN CAUTION THE BAR AND THE SPANNER TO AVOID DAMAGING THE FORMER.
Page 191 8 - CHASSIS INSPECTING THE FRONT FORKS 1. Check: - The degree of wear on the suspension bar guide bush. Re- new it in the event of it being damaged on over 30% of its total surface. - With the aid of some X-shaped chocks and a comparison meter fitted on a fixed support, determine the degree of wear on the bar.
Page 192 8 - CHASSIS FITTING FRONT SUSPENSION...
Page 193 8 - CHASSIS FRONT SUSPENSION FITTING 1. Position: - The oil seal. APPLY A LITTLE HYDRAULIC FLUID N.B. TO THE EDGES OF THE OIL SEAL TO AID ITS FITTING. 2. Insert: - The oil seal into the fork arm (2) using the tool (1). Use a 52Ø...
Page 194 8 - CHASSIS 6. Insert: - Hydraulic fluid. Quantity of oil: 390 ml ±5 ml. Type of oil: SAE 7.5 W AS THE FLUID IS BEING INSERTED, N.B. PUMP THE STEM UP AND DOWN TO EXPEL THE AIR. 7. Fit: - The top locking bolt, holding the locknut.
Page 195: Steering
8 - CHASSIS INSPECTING THE STEERING COLUMN 1. Raise: - The front wheel by putting a suitable support under the engine. 2. Hold: - The end of the front forks and gently swing the fork as- sembly. Loose => Adjust the steering column. 8.4 - STEERING 1.
Page 196 8 - CHASSIS DISMANTLING THE SEMI-HANDLEBARS RIGHT-HAND SEMI-HANDLEBAR 1. Remove: - The starter switch assembly (1). - The front brake control assembly (2) - The handlebar counterweight (3). - The throttle twist grip (4). 2. Remove: - The semi-handlebar securing bolts (5). - The semi-handlebar.
Page 197 8 - CHASSIS FITTING THE SEMI-HANDLEBARS 1. Fit: - The components corresponding to the side to be fitted. 2. Fit: - The semi-handlebars onto the top plate. Fitting torques: - The semi-handlebar nut to the plate: 17 – 19 N.m with sealer (1,7 – 1,9 kgf.m) - Counterweight to handlebars: 3,5 –...
Page 198: Rear Wheel
8 - CHASSIS 8.5 - REAR WHEEL ENSURE THAT THE MOTOR- WARNING CYCLE IS SUPPORTED FIRMLY, AND THERE IS NO RISK OF IT FALLING. PUT THE MOTORCYCLE ON A FLAT SURFACE. IF THE BRAKE LEVER/PEDAL IS CAUTION APPLIED WITHOUT THE WHEEL BEING FITTED, THE CORRESPON- DING SYSTEM WILL HAVE TO BE BLED.
Page 199 8 - CHASSIS FITTING THE REAR WHEEL Take note of the following points: 1. Lubricate: - The rear wheel shaft. - The bearing. - The retaining rings. Recommended lubricant: Lithium soap based grease 2. Fit: - Rear wheel. - The rear wheel shaft. - Calliper and bracket.
Page 200: Rear Suspension
8 - CHASSIS 8.6 - REAR SUSPENSION INSPECTING THE REAR SUSPENSION 1. Inspect: - The swinging arm play. Play => Tighten the joint shaft nut or replace the bushes. - Swinging arm vertical movement Irregular movement/warping/stains => Renew the bushes. - Swinging arm vertical movement 2.
Page 201 8 - CHASSIS 3. Remove: - The shock absorber through the bottom cavity between the rear wheel and the exhaust pipe. FITTING THE REAR SUSPENSION Reverse the dismantling procedure Shock absorber top securing device: 55-65 Nm (5.5-6.5 kgfm) Shock absorber bottom securing device: 55-65 Nm (5.5-6.5 kgfm) - apply Loctite 243-type thread sealant. USE TOOL CODE NO.
Page 202 9 - BRAKING SYSTEM 9 - BRAKING SYSTEM 9.1 - FRONT BRAKE ................9.2 - REAR BRAKE .................
Page 203: Front Brake
9 - BRAKING SYSTEM 9.1 - FRONT BRAKE DISMANTLING BRAKE CALLIPER PLACE A RECIPIENT UNDER N.B. THE CALLIPER TO COLLECT THE BRAKE FLUID. REMOVE THE CALLIPER FROM THE FORKS TO PREVENT BRAKE FLUID FROM FALLING ONTO THE DISK. 1. Unscrew: - The two bolts (2) from the calliper and separate the calliper backwards from the disk.
Page 204 9 - BRAKING SYSTEM 5. Check: - The brake fluid level. - The condition of the braking force to see if any resistance is noted or any loss of fluid. Functioning correctly => Refit the fluid reservoir cover. Brake fluid cover screws: 1 ÷...
Page 205 9 - BRAKING SYSTEM FITTING THE FRONT BRAKE WHEEL CYLINDER 1. Fit: - The banjo bolt (1). - The 2 bolts and the front brake lever assembly. 2. Tighten: - The brake pipe banjo bolt. - The 2 bolts and the front brake lever assembly. Brake hose banjo bolt: 25 ÷...
Page 206 9 - BRAKING SYSTEM CHECKING THE BRAKE LEVER MASTER CYLINDER (VISUAL CHECK): 1. Remove: - The master cylinder (Extracting the front master cylinder). 2. Remove: - The front master cylinder. 3. Check: - That there are no scratches, corrosion or holes on the inner walls of the master cylinders and on the outer part of each piston.
Page 207 9 - BRAKING SYSTEM FITTING THE FRONT BRAKE DISK 1. Position: - The disk so that side (2) is facing outwards. APPLY LOCTITE 243-TYPE WARNING THREAD SEALANT TO THE THREADS OF THE BRAKE DISK MOUNTING BOLTS. 2. Tighten: - The front brake disk mounting bolts (1). Nominal tightening torque: 1,0-1,2 Kgf.m (10-12 N.m) Apply Locktite 243-type thread sealant.
Page 208 9 - BRAKING SYSTEM FRONT BRAKE DISK DISTORTION 1. Check: - Place a dial gauge against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is tur- ned (B) by hand. - If the deviation from centre exceeds the service limit, re- new the disk.
Page 209 9 - BRAKING SYSTEM 4. Bleed: - The air completely from the master cylinder using this procedure. 5. Remove: - The transparent plastic cap from the bleed nipple (3) and refill from the other end of the hose (lever reservoir). 6.
Page 210 9 - BRAKING SYSTEM 12. Tighten: - The bleed valve (3). Bleed nipple: 4 ÷ 8 N.m (0,4 ÷ 0,8 kgf.m) 13. Check: - The brake fluid level through the inspection window (4). - Once the bleeding process has been carried out, check the efficiency of the brake to see if there is any resistance or any fluid loss.
Page 211: Rear Brake
9 - BRAKING SYSTEM 9.2 - REAR BRAKE DISMANTLING THE BRAKE CALLIPER PLACE A CONTAINER UNDER THE N.B. CALLIPER TO COLLECT THE BRAKE FLUID. 1. Firstly remove: - The rear wheel. 2. Unscrew: - The two bolts (2) securing the calliper to the bracket. 3.
Page 212 9 - BRAKING SYSTEM 4. Bleed: - The brake system pipe. Bleed nipple: 4 ÷ 8 N.m (0,4 ÷ 0,8 kgf.m) 5. Check: - The brake fluid level. - The condition of the braking force to see if any resistance is noted or any loss of fluid. Functioning correctly =>...
Page 213 9 - BRAKING SYSTEM FITTING THE REAR BRAKE WHEEL CYLINDER 1. Fit: - The banjo bolt (1). - Nominal tightening torque: 2. Apretar: - El perno banjo (1) del manguito del freno. - Los 2 tornillos (2) del soporte. Brake hose banjo bolt: 25 ÷...
Page 214 9 - BRAKING SYSTEM CHECKING THE BRAKE LEVER MASTER CYLINDER (VISUAL CHECK): 1. Remove: - The master cylinder (Extracting the front master cylinder). 2. Remove: - The front master cylinder. 3. Check: - That there are no scratches, corrosion or holes on the inner walls of the master cylinders and on the outer part of each piston.
Page 215 9 - BRAKING SYSTEM FITTING THE REAR BRAKE DISK 1. Position: - The disk so that side (2) is facing outwards. APPLY LOCTITE 243-TYPE WARNING THREAD SEALANT THREADS OF THE BRAKE DISK MOUNTING BOLTS. 2. Tighten: - The front brake disk mounting bolts (1). Nominal tightening torque: 1,0-1,2 Kgf.m (10-12 N.m) Apply Locktite 243-type thread sealant.
Page 216 9 - BRAKING SYSTEM REAR BRAKE DISK DISTORTION 1. Check: - Place a dial gauge against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is tur- ned (B) by hand. - If the deviation from centre exceeds the service limit, re- new the disk.
Page 217 9 - BRAKING SYSTEM BLEEDING THE BRAKE SYSTEM PIPE The brake fluid has a very low compression coefficient, with the result that almost all the movements of the brake lever are transmitted directly to the calliper for braking. Air however compresses easily.
Page 218 9 - BRAKING SYSTEM CHECK THE FLUID LEVEL FRE- N.B. QUENTLY DURING THE BLEE- DING OPERATION AND RE- PLENISH THE RESERVOIR WITH BRAKE FLUID WHEN NECES- SARY. IF THE RESERVOIR EMPTIES COMPLE- TELY OF FLUID AT ANY TIME DURING THE BLEEDING OPE- RATION, PERFORM THE BLEE- DING PROCEDURE ALL OVER AGAIN FROM THE BEGINNING,...
Page 219 9 - BRAKING SYSTEM WARNING TAKE THE PRECAUTIONS LISTED BELOW: 1) NEVER RE-USE BRAKE FLUID. 2) DO NOT USE FLUID FROM A CONTAINER THAT HAS BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PROLONGED PERIOD OF TIME. 3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR USE IN THE BRAKE. THIS REDUCES THE BRAKE FLUID BOILING POINT AND MAY RESULT IN THE BRAKES NOT WORKING EFFICIENTLY.
Page 220 10 - ELECTRICAL SYSTEM 10 - ELECTRICAL SYSTEM 10.1 - GENERAL INDICATIONS ............10.2 - LOCATING ELECTRICAL COMPONENTS ........ 10.3 - WIRING DIAGRAM ..............10.4 - CHARGING SYSTEM ..............10.5 - IGNITION SYSTEM ..............10.6 - STARTER MOTOR SYSTEM ............10.7 - INSTRUMENT PANEL ..............
Page 221: General Indications
10 - ELECTRICAL SYSTEM 10.1 - GENERAL INDICATIONS CHECKING CONNECTORS Check for corrosion, damp etc. in the connectors. 1. Disconnect: - Connectors. 2. Dry: - Each of the terminals with compressed air. 3. Connect and disconnect: - The connector two or three times. 4.
Page 222 10 - ELECTRICAL SYSTEM SWITCH CONNECTIONS SHOWN IN THIS MANUAL This manual contains connection tables like the one in the figure on the left, showing the switch terminal connections (main switch, brake switch, light switch, etc.). The column on the far left indicates the different switch po- sitions, the top line indicates the colours of the conductors connected to the switch terminals.
Page 223: Locating Electrical Components
10 - ELECTRICAL SYSTEM 10.2 - LOCATING ELECTRICAL COMPONENTS 1 HORN 2 INSTRUMENT PANEL 3 HT COIL ASSY. 4 BATTERY 5 FUSES 6 INDICATOR LIGHT 7 MAIN RELAY 8 DIODE 9 NUMBER PLATE LIGHT 10 STARTER RELAY 11 TURN INDICATORS 12 REGULATOR 13 CDI UNIT 14 SIDELIGHT ASSY.
Page 224: Wiring Diagram
WIRING DIAGRAM - GPR 125 4T Headlight assembly Bulb 12V 55W H11 Speedometer Led lighting bulb c/Km. Led neutral pilot light Led turn incicator control pilot ligh Led hight beam control pilot light Led oil indicator Led fuel sensor Led water temp Keyswitch Front right- rear left turn ind.
Page 225: Charging System
10 - ELECTRICAL SYSTEM 10.4 - CHARGING SYSTEM COMPONENTS The main elements of the charging system are: - Magneto: This is a three-phase element generating alternating current. - Current rectifying regulator: This has the job of rectifying the alternating current generated by the mag- neto to direct current in order to charge the battery.
Page 226: Ignition System
10 - ELECTRICAL SYSTEM 10.5 - IGNITION SYSTEM DESCRIPTION OF THE SYSTEM Logic of the system - The fundamental parameter is the rpm reading from the engine revs sensor (pick-up) - Based on the information from this sensor, the CDI unit calculates the moment in which the spark plug should fire (ignition advance).
Page 227 10 - ELECTRICAL SYSTEM - Ignition unit (CDI unit) Current discharge to the primary winding of the ignition coil via the Green/Black (GR/B) cable. The unit receives power (+) from the main relay via the Red/ Green (R/GR) cable. The unit’s earth connection is via the Yellow/Green (Y/GR) cable.
Page 228: Instrument Panel
10 - ELECTRICAL SYSTEM 10.7 - INSTRUMENT PANEL The instrument panel incorporates the following functions: • Instant speed display • Tachometer. • Maximum RPM programming with flashing light. • Maintenance requirement indicator light (service). • Maximum speed display. • Indication in KM or Miles. •...
Page 229 10 - ELECTRICAL SYSTEM ADJUSTING THE TIME The time is adjusted as follows: 1. To display total kilometres 2. Press the “MODE” button for 3 seconds. The minutes indication will disappear 3. Press the “MODE” button to increase the hours until the desired hour is reached 4.
Page 230 10 - ELECTRICAL SYSTEM The layout of the LCD screen for this application is the following: All the dashboard functions are controlled using a single MODE button. This should be pressed briefly to change from one function to another, or held down to define the different adjustments. The diagram for the steps in the user interface is the following: On switching on the ignition once again, the dashboard should display the last function displayed when it was switched off.
Page 231 10 - ELECTRICAL SYSTEM CONNECTIONS The functions of the connectors are the following: VALUE FUNCTIONS DASHBOARD EARTH LEFT-HAND TURN INDICATOR INPUT RIGHT-HAND TURN INDICATOR INPUT SPEED SENSOR INPUT MAIN BEAM INPUT RESERVE SENSOR INPUT EARTH FOR SENSORS 125 CC RPM INPUT PROP-STAND INPUT MODE INPUT LINE K...
Page 232 10 - ELECTRICAL SYSTEM RESETTING SERVICE INDICATOR 1- Once the machine has travelled the distance set out on the table below, the system will activate the inspection function, which appears on the display in the form of the following icon: 2- Service intervals FIRST WARNING 1000 Kms...
Page 233 10 - ELECTRICAL SYSTEM 5- The code 423 should now be entered. The first figure will change from 0 to 9 one second at a time. When the figure arrives at the desired number (in the case of the example, 4), press MODE to save in memory: 6- The second figure will begin to change (in this case, halt it when it reaches 2): 7- Do the same with the third figure (halt it when it reaches 3):...
Page 234 10 - ELECTRICAL SYSTEM 9- The change from kilometres to miles or vice versa is done by holding down the MODE button for over three seconds. 10- The following function is the one for resetting service/total km. To do so, pressing MODE briefly will display the follo- wing: 11- The icon with the spanner symbol will only appear when a service is overdue.
Page 235: Lighting And Indicating
10 - ELECTRICAL SYSTEM 10.8 - LIGHTING AND INDICATING ADJUSTING THE HEADLIGHT BEAM (RIGHT-LEFT) 1. Firstly remove: * The instrument panel cover and the instrument panel. 2. Adjust: -To adjust the height, adjust screw (A) on both sides. SCREWING IN => Lower SCREWING OUT =>...
Page 236 10 - ELECTRICAL SYSTEM KEEP INFLAMMABLE PRODUCTS AND HANDS AWAY FROM THE BULB WHILE WARNING IT IS LIT, BECAUSE IT IS HOT. DO NOT TOUCH IT UNTIL IT COOLS DOWN. AVOID TOUCHING THE BULB GLASS. KEEP FREE OF OIL. IF NOT, THE TRANS- CAUTION PARENCY OF THE GLASS, THE LIFETIME OF THE BULB AND THE AMOUNT OF LIGHT EMITTED WILL BE AFFECTED.
Page 237 10 - ELECTRICAL SYSTEM CHANGING THE REAR LIGHT DISMANTLING 1. Firstly remove: * The seat, the pillion passenger seat, the upper cowling cover and the cowling. 2. Remove: - The battery (only withdraw it). 3. Remove: - The main relay (A). - The starter relay (B).
Page 238 10 - ELECTRICAL SYSTEM 5. Remove: - The 3 bolts on the rear light bracket cover. 6. Disconnect: - The rear light from the general wiring. 7. Unscrew: - The rear light and remove it.
Page 239 10 - ELECTRICAL SYSTEM CHANGING THE TURN INDICATOR BULBS 1. Unscrew: - Glass cover screw. 2. Remove: - The glass cover. 3. Remove: - The bulb by pushing it in and turning it to the left. Bulb type: 12v 10W CHANGING THE HORN DISMANTLING 1.
Page 240 10 - ELECTRICAL SYSTEM CHANGING THE NUMBER PLATE LIGHT DISMANTLING 1. Remove: - The rear reflector by means of the 2 screws located inside. 2. Remove: The rear mudguard supplementary support. 3. Remove: - The nut and bolt (inside). - The number plate light. 4.
Page 241: Fitting New Components
10 - ELECTRICAL SYSTEM 10.9 - FITTING NEW COMPONENTS CHANGING THE DIODE DISMANTLING 1. Firstly remove: * The seat, the pillion passenger seat, the upper cowling cover and the cowling. 2. Disconnect: - The diode. CHANGING THE REGULATOR DISMANTLING 1. Remove: - The front bolt on the tank and tilt it backwards.
Page 242 10 - ELECTRICAL SYSTEM CHANGING THE CDI UNIT DISMANTLING 1. Remove: - The front bolt on the tank and tilt it backwards (see the first image in the previous section). ON CONNECTING OR DISCON- N.B. NECTING THE CDI UNIT, ALWAYS DO SO WITH THE BATTERY DIS- CONNECTED FROM THE WIRING.
Page 243 10 - ELECTRICAL SYSTEM CHANGING THE MAIN RELAY DISMANTLING 1. Firstly remove: * The seat and the pillion passenger seat. 2. Remove: - The fuse box for ease of access. 3. Remove: - Pull the relay out while holding down the connector strip. CHANGING THE INSTRUMENT PANEL DISMANTLING 1.
Page 244 10 - ELECTRICAL SYSTEM CHANGING THE HT COIL DISMANTLING 1. Remove: - The front bolt on the tank and tilt it backwards. 2. Unplug: - The spark plug connector, by pulling it off firmly. 3. Disconnect: - The coil cables. 4.
Page 245: Inspecting The Battery And Fuses
10 - ELECTRICAL SYSTEM 10.10 - INSPECTING THE BATTERY AND FUSES INSPECTING THE BATTERY DISMANTLING 1. Firstly remove: * The seat and the pillion passenger seat. 2. Inspect: - The battery terminals. Dirtiness => Clean with wire brush. Poor connection => Put right. AFTER CLEANING THE TERMI- N.B.
Page 246 10 - ELECTRICAL SYSTEM INSPECTING THE FUSES DISCONNECT THE MAIN SWIT- CH WHEN INSPECTING OR RE- CAUTION NEWING A FUSE. FAILURE TO DO SO MAY RESULT IN A SHORT CIRCUIT. THE ELECTRICAL SYSTEM HAS 2 N.B. FUSES: -ONE 20A FUSE: THE MAIN FUSE -ONE 20A FUSE: THE SECONDA- RY FUSE DISMANTLING...
Page 247 Rev.0 - 2009...

Derbi GPR125 Workshop Manual

1 Special Tools for the Engine

2 PDI (Pre-Delivery Inspection)

3 Periodical Maintenance Table

5 Checking Level of the Float Chamber

8 Front Suspension

10 Ignition System

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