PIAGGIO Runner 125 Service Station Manual
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PIAGGIO Runner 125 Service Station Manual

633616 (it),633617 (en), 633618 (fr),633619 (de), 633620 (es),633621 (pt), 633622 (nl),633623 (el)
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SERVICE STATION MANUAL
633616 (IT)-633617(EN)-633618 (FR)-633619
(DE)-633620 (ES)- 633621 (PT)- 633622 (NL)- 633623
(EL)
Runner 125 - 200

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Summary of Contents for PIAGGIO Runner 125

  • Page 1 SERVICE STATION MANUAL 633616 (IT)-633617(EN)-633618 (FR)-633619 (DE)-633620 (ES)- 633621 (PT)- 633622 (NL)- 633623 (EL) Runner 125 - 200...
  • Page 2 Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 Runner 125 - 200 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM IRGIN CIRCUIT IAGNOSTIC CODES IAGNOSTIC CODE FLASH IAGNOSTIC CODE FLASHES IAGNOSTIC CODE FLASHES GNITION CIRCUIT ATTERY RECHARGE CIRCUIT TATOR CHECK OLTAGE REGULATOR CHECK ECHARGE SYSTEM VOLTAGE CHECK URN SIGNALS SYSTEM CHECK USES ASHBOARD...
  • Page 6 UMP ELECTRICS CHECK ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.

  • Page 9: Vehicle Identification

    Runner 125 - 200 Characteristics Vehicle identification Vehicle 125 Chassis prefix: ZAPM46300 ÷ 1001 Engine prefix: M463M Vehicle 200 Chassis prefix: ZAPM46400 ÷ 1001 Engine prefix: M464M Dimensions and mass EIGHT AND DIMENSIONS Specification Desc./Quantity Kerb weight 137 ± 5 kg...

  • Page 10: Technical Data

    Runner 125 - 200 Characteristics Engine TECHNICAL DATA 125 Specification Desc./Quantity Engine single-cylinder, four-stroke Bore x stroke 57 x 48.6 mm Cubic capacity 124 cm³ Compression ratio 11.5 ÷ 12.5 : 1 Ignition advance (before TDC) From 10° ± 1° at 2000 rpm to 34° ± 1° at 6500 rpm...

  • Page 11: Electrical Components

    Runner 125 - 200 Characteristics Specification Desc./Quantity Cubic capacity 198 cm³ Compression ratio 11 ÷ 12 : 1 Ignition advance (before TDC) From 10° ± 1° at 2000 rpm to 32° ± 1° at 6500 rpm Kehin Carburettor CVEK-30 Max. speed...

  • Page 12: Wheels And Tyres

    Runner 125 - 200 Characteristics Frame and suspensions FRAME AND SUSPENSIONS Specification Desc./Quantity Chassis Modular double cradle frame made of welded tubular steel with sheet metal reinforcement. Front suspension hydraulic double-acting telescopic fork with 35 mm stems Rear suspension With coaxial spring and hydraulic shock absorber. Chassis to engine support with swinging arm.

  • Page 13: Tightening Torques

    Runner 125 - 200 Characteristics Specification Desc./Quantity Minimum mixture set screw initial opening Tapered pin stamping NDYA Diffuser nozzle Ø 2.8 Starter air jet Ø 1.5 (body) Starter diffuser nozzle Ø 1.5 (body) Starter jet ~ 20 Ω (at 24°)

  • Page 14: Rear Brake

    Runner 125 - 200 Characteristics Name Torque in Nm M14 Ø 8.8 steel screw Iron, steel REAR BRAKE Name Torque in Nm Rear brake disc screws(°) 5 ÷ 6.5 Rear brake calliper-pipe fitting 20 ÷ 25 Rigid / flexible pipe fitting 13 ÷...

  • Page 15: Engine - Flywheel

    Runner 125 - 200 Characteristics Name Torque in Nm Crankcase timing system cover screws (°) 3.5 ÷ 4.5 ENGINE - FLYWHEEL Name Torque in Nm Pick-Up clamping screws 3 ÷ 4 Stator assembly screws (°) 3 ÷ 4 Flywheel cover fixing screws...
  • Page 16 Runner 125 - 200 Characteristics Cylinder - piston assy. ENGINE 200 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder / piston 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044...

  • Page 17: Piston Rings

    Runner 125 - 200 Characteristics ENGINE 125 COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 ÷ 57.004 56.945 ÷ 56.952 0.045 - 0.059 Cylinder 57.004 ÷ 57.011 56.952 ÷ 56.959 0.045 - 0.059 Piston 57.011 ÷ 57.018 56.959 ÷...
  • Page 18 Runner 125 - 200 Characteristics Name Description Dimensions Initials Quantity Spacer tool 51.4 +0.05 D = 0.20 - 0.50 Slot packing system 200 models Characteristic Compression ratio, 200 models 11.5 ± 0.5 : 1 Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder.
  • Page 19 Runner 125 - 200 Characteristics Characteristic Compression ratio, 125 models 12 ± 0.5: 1 Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.
  • Page 20 Runner 125 - 200 Characteristics Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed by the piston crown protrudes from the plane formed by the upper part of the cylinder. The further the piston protrudes from the cylinder, the thicker the base gasket to be used (to restore the compression ratio) and vice versa.
  • Page 21 Runner 125 - 200 Characteristics Measurement «A» to be taken, is a value of piston re-entry. It indicates by how much the plane formed by the piston crown descends below the plane formed by the upper part of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.
  • Page 22 Runner 125 - 200 Characteristics Oversizes ENGINE 125 OVERSIZE Name Description Dimensions Initials Quantity Compression ring 57 x 1 0.15 ÷ 0.30 Oil scraper ring 57 x 1 0.10 ÷ 0.30 Oil scraper ring 57 x 2.5 0.15 ÷ 0.35 Compression ring 1st 57.2 x 1...
  • Page 23 Runner 125 - 200 Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP CITY HI TEC 4T Four-stroke engine oil Lubricating oil for flexible shafts (throttle...

  • Page 24: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 25 Runner 125 - 200 Tooling APPROPRIATE TOOL Stores code Description 020151Y Air heater 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 001467Y014 Pliers to extract ø 15-mm bearings TOOL - 25...
  • Page 26 Runner 125 - 200 Tooling Stores code Description 020412Y 15 mm guide 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47-mm adaptor TOOL - 26...
  • Page 27 Runner 125 - 200 Tooling Stores code Description 020363Y 20 mm guide 020459Y Punch for fitting bearing on steering tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting TOOL - 27...
  • Page 28 Runner 125 - 200 Tooling Stores code Description 020382Y011 adapter for valve removal tool 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch for assembling valve seal rings 020360Y Adaptor 52 x 55 mm...
  • Page 29 Runner 125 - 200 Tooling Stores code Description 020364Y 25-mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020444Y Tool for fitting/ removing the driven pulley clutch 020330Y Stroboscopic light to check timing 001467Y035 Belle for OD 47-mm bearings...
  • Page 30 Runner 125 - 200 Tooling Stores code Description 020368Y driving pulley lock wrench 020319Y Immobilizer check tester 020287Y Clamp to assemble piston on cylinder 020263Y Sheath for driven pulley fitting 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool TOOL - 30...
  • Page 31 Runner 125 - 200 Tooling Stores code Description 020428Y Piston position check support 020426Y Piston fitting fork 020425Y Punch for flywheel-side oil seal 020423Y driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston fitting band TOOL - 31...
  • Page 32 Runner 125 - 200 Tooling Stores code Description 020382Y Valve cotters equipped with part 012 re- moval tool 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y 32 x 35 mm adaptor...
  • Page 33 Runner 125 - 200 Tooling Stores code Description 020409Y Multimeter adaptor - Peak voltage detec- tion 020456Y Ø 24 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut TOOL - 33...
  • Page 34 Runner 125 - 200 Tooling Stores code Description 002465Y Pliers for circlips 001330Y Tool for fitting steering seats 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020444Y011 adapter ring 020444Y009 46x55 Wrench 001467Y...
  • Page 35 Runner 125 - 200 Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bearings 020444Y010 adapter ring 494929Y Exhaust fumes analyser TOOL - 35...
  • Page 36 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 37: Maintenance Chart

    Runner 125 - 200 Maintenance Maintenance chart MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C. CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE Clean the SAS air filter every 2 years * Check level every 3,000 km...
  • Page 38 Runner 125 - 200 Maintenance Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condi- tion.

  • Page 39: Checking The Spark Advance

    Runner 125 - 200 Maintenance Checking the spark advance - To check ignition advance, use the stroboscopic light with induction pincers connected to the spark plug power wire. - Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug).
  • Page 40 Runner 125 - 200 Maintenance From 10° ± 1° at 2000 rpm Spark advance variation ERSION Specification Desc./Quantity Version 200 : Operation threshold First threshold : 9900 ±50 Second threshold : 10100 ±50 Version 200 : Reactivation threshold First threshold : 9800 ±50 Second threshold: 10000 ±50...

  • Page 41: Spark Plug

    Runner 125 - 200 Maintenance Spark plug To service the spark plug the engine must be cold, proceed as follows: - Remove the right fairing undoing the 4 screws - Remove the spark plug cap. - Use the supplied spanner (with retaining rubber ring) to remove the spark plug.
  • Page 42 Runner 125 - 200 Maintenance THE SPARK PLUG MUST BE REMOVED WHEN THE MO- TOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 12,000 KM. THE USE OF NON CONFORMING IGNI- TION CONTROL UNITS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE EN- GINE.
  • Page 43 Runner 125 - 200 Maintenance Replacement -Remove the oil cap «A». - Unscrew the oil drainage cap "B" and drain out all the oil. - Screw in the drainage cap again and fill the hub with the prescribed oil. Recommended products...

  • Page 44: Air Filter

    Runner 125 - 200 Maintenance Air filter Remove the air cleaner cap after undoing the re- tainer screws, then extract the filter. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- pressed air.
  • Page 45 Runner 125 - 200 Maintenance Refit the new cartridge filter being careful to lubri- cate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, oil must be filled from cap "A". Then start...

  • Page 46: Oil Pressure Warning Light

    Runner 125 - 200 Maintenance Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx.

  • Page 47: Checking The Valve Clearance

    Runner 125 - 200 Maintenance Checking the valve clearance -To check valve clearance, centre the reference marks of the timing system - Use a thickness gauge to check that the clear- ance between the valve and the register corre- sponds with the indicated values. When the valve...

  • Page 48: Recommended Products

    Under normal climatic conditions, the liquid should be replaced every two years. This operation must be carried out by trained technicians, please con- tact an Authorised Piaggio-Gilera Service Cen- CAUTION TOP UPS SHOULD ONLY BE CARRIED OUT WITH DOT 4 CLASSIFIED BRAKE FLUID.

  • Page 49: Headlight Adjustment

    Runner 125 - 200 Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen;...
  • Page 50 Runner 125 - 200 Maintenance System description: The air is drawn through a passage behind the secondary air box cover, passes through that cover and flows towards the valve. Now the filtered air enters the diaphragm valve to be channelled towards the head.
  • Page 51 Runner 125 - 200 Maintenance - Check that the sas valve plastic support is not dented or distorted - Check the integrity of the rubber gasket between the valve and the sas air filter support. - Clean the filter thoroughly. Replace the filter if it is damaged or distorted.
  • Page 52 Runner 125 - 200 Maintenance Fix the metal tube to the head using the gasket and the 2 screws. Lock the lower clamp connecting manifold / pipe. MAIN - 52...
  • Page 53 Runner 125 - 200 Maintenance MAIN - 53...

  • Page 54: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 55: Difficult Starting

    Runner 125 - 200 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty;...
  • Page 56 Runner 125 - 200 Troubleshooting Possible Cause Operation Battery flat Check the charge of the battery, if there are any sulphur marks, replace and use the new battery following the instructions shown in the chapter Intake coupling cracked or clamps incorrectly tightened...

  • Page 57: High Fuel Consumption

    Runner 125 - 200 Troubleshooting Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Excessive exhaust noise EXCESSIVE EXHAUST NOISE Possible Cause Operation Secondary air device cut-off valve not working Replace the secondary air device...

  • Page 58: Brakes Overheating

    Runner 125 - 200 Troubleshooting Insufficient braking NSUFFICIENT BRAKING Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits;...

  • Page 59: Rear Wheel

    Runner 125 - 200 Troubleshooting Rear wheel REAR WHEEL ROTATES WITH ENGINE AT IDLE Possible Cause Operation Idling rpm too high Adjust the engine idle speed. Clutch fault Check the springs / clutch masses Controls STEERING CONTROLS AND SUSPENSIONS Possible Cause...

  • Page 60: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 61 Runner 125 - 200 Electrical system KEY (With electric pump) 1. Electronic ignition device 2. Immobilizer aerial 3. Magneto flywheel - Pick-up 4. Voltage regulator 5. Fuses 6. Battery 7. Starter motor 8. Start-up remote control switch 9. Start-up button 10.
  • Page 62 Runner 125 - 200 Electrical system 18. Headlight assembly A. Tail light bulbs B. High-beam light bulbs C. Low-beam light bulb 19. Right front turn indicator 20. Horn 21. Horn button 22. Thermistor 23.Wheel turning sensor 24. Instrument panel 1. +Battery 2.
  • Page 63 Runner 125 - 200 Electrical system 6. Engine revs 32. Automatic starter 33. Key switch 34. Starter control winding 35. Spark plug 36. HV coil KEY (Without electric pump) 1. Electronic ignition device 2. Immobilizer aerial 3. Magneto flywheel - Pick-up 4.
  • Page 64 Runner 125 - 200 Electrical system 14. Rear left turn indicator 15. Rear light A. Tail light bulbs B. Stop light bulbs 16. Rear right turn indicator 17. Left front turn indicator 18. Headlight assembly A. Tail light bulbs B. High-beam light bulbs C.
  • Page 65 Runner 125 - 200 Electrical system 30. Fuel pump 31. Automatic starter 32. Key switch 33. Starter control winding 34. Spark plug 35. HV coil Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:...
  • Page 66 Runner 125 - 200 Electrical system 36. HV coil KEY (Without electric pump) 1. Electronic ignition device 2. Immobilizer aerial 5. Fuses 6. Battery 32. Key switch 34. Spark plug 35. HV coil ELE SYS - 66...
  • Page 67 Runner 125 - 200 Electrical system Headlights and automatic starter section KEY (With electric pump) 1. Electronic ignition device 5. Fuses 6. Battery 13. License plate light 15. Rear light A. Tail light bulbs B. Stop light bulbs 18. Headlight assembly A.
  • Page 68 Runner 125 - 200 Electrical system 6. Hall 7. Lighting 8. Enable gauge 10. Rev counter 11. Coolant level 12. Fuel level 13. High-beam warning light 14. Right turn indicator 15. Left turn indicator 16. Oil reserve warning light 17. Low fuel warning light 20.
  • Page 69 Runner 125 - 200 Electrical system 13. License plate light 15. Rear light A. Tail light bulbs B. Stop light bulbs 18. Headlight assembly A. Tail light bulbs B. High-beam light bulbs C. Low-beam light bulb 24. Instrument panel 1. +Battery 2.
  • Page 70 Runner 125 - 200 Electrical system Battery recharge and starting KEY (With electric pump) 1. Electronic ignition device 3. Magneto flywheel - Pick-up 4. Voltage regulator 5. Fuses 6. Battery 7. Starter motor 8. Start-up remote control switch 9. Start-up button 10.
  • Page 71 Runner 125 - 200 Electrical system KEY (Without electric pump) 1. Electronic ignition device 3. Magneto flywheel - Pick-up 4. Voltage regulator 5. Fuses 6. Battery 7. Starter motor 8. Start-up remote control switch 9. Start-up button 10. Stop button on rear brake 11.
  • Page 72 Runner 125 - 200 Electrical system Level indicators and enable signals section KEY (With electric pump) 1. Electronic ignition device 2. Immobilizer aerial 5. Fuses 6. Battery 22. Thermistor 23.Wheel turning sensor 24. Instrument panel 1. +Battery 2. +Key 3. Ground 4.
  • Page 73 Runner 125 - 200 Electrical system 12. Fuel level 13. High-beam warning light 14. Right turn indicator 15. Left turn indicator 16. Oil reserve warning light 17. Low fuel warning light 20. Immobilizer LED 25. Engine oil pressure sensor 26. Fuel level transmitter 33.

  • Page 74: Devices And Accessories

    Runner 125 - 200 Electrical system 3. Ground 4. -Hall 5. +Hall 6. Hall 7. Lighting 8. Enable gauge 10. Rev counter 11. Coolant level 12. Fuel level 13. High-beam warning light 14. Right turn indicator 15. Left turn indicator 16.
  • Page 75 Runner 125 - 200 Electrical system KEY (With electric pump) 1. Electronic ignition device 5. Fuses 6. Battery 12. Turn indicator switch 14. Rear left turn indicator 16. Rear right turn indicator 17. Left front turn indicator 19. Right front turn indicator 20.
  • Page 76 Runner 125 - 200 Electrical system 10. Rev counter 11. Coolant level 12. Fuel level 13. High-beam warning light 14. Right turn indicator 15. Left turn indicator 16. Oil reserve warning light 17. Low fuel warning light 20. Immobilizer LED 28.

  • Page 77: Checks And Inspections

    Runner 125 - 200 Electrical system 1. Electronic ignition device 5. Fuses 6. Battery 12. Turn indicator switch 14. Rear left turn indicator 16. Rear right turn indicator 17. Left front turn indicator 19. Right front turn indicator 20. Horn 21.
  • Page 78 Runner 125 - 200 Electrical system Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit.

  • Page 79: Index Of Topics

    INDEX OF TOPICS IRGIN CIRCUIT...
  • Page 80 Runner 125 - 200 Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised if the control unit has been programmed properly. The data storage pro-...
  • Page 81 Runner 125 - 200 Virgin circuit thoroughly inspected: In any case it is advisable to use resistive spark plugs. Characteristic MASTER key: RED KEY WITH BIG HANDGRIP SERVICE key. RED KEY WITH SMALL HANDGRIP - 81...

  • Page 82: Diagnostic Codes

    INDEX OF TOPICS IAGNOSTIC CODES...
  • Page 83 Runner 125 - 200 Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
  • Page 84 Runner 125 - 200 Diagnostic codes - 84...

  • Page 85: Diagnostic Code

    INDEX OF TOPICS IAGNOSTIC CODE FLASH...
  • Page 86 Runner 125 - 200 Diagnostic code - 1 flash The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if nec- essary. - 86...
  • Page 87 INDEX OF TOPICS IAGNOSTIC CODE FLASHES...
  • Page 88 Runner 125 - 200 Diagnostic code - 2 flashes A two-flash code shows a system where the con- trol unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary.
  • Page 89 INDEX OF TOPICS IAGNOSTIC CODE FLASHES...
  • Page 90 Runner 125 - 200 Diagnostic code - 3 flashes A three-flash code indicates a system where the control unit does not recognise the key. Turn the switch to ON using several keys: if the error code is repeated even with the Master key, replace the control unit.

  • Page 91: Ignition Circuit

    INDEX OF TOPICS GNITION CIRCUIT...
  • Page 92 Runner 125 - 200 Ignition circuit Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system im- mediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system.
  • Page 93 INDEX OF TOPICS ATTERY RECHARGE CIRCUIT...
  • Page 94 Runner 125 - 200 Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery's positive terminal passing through the 20A protective fuse.

  • Page 95: Stator Check

    INDEX OF TOPICS TATOR CHECK...
  • Page 96 Runner 125 - 200 Stator check - With a tester, check the circuit between connec- tions 5-3 and 5-1 is not interrupted. - Check the earth isolation on the three phases of stators 5-earth, 3-earth, 1-earth. Stage indicative resistance: 0.7 - 0.9 Ω...
  • Page 97 INDEX OF TOPICS OLTAGE REGULATOR CHECK...
  • Page 98 Runner 125 - 200 Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator.
  • Page 99 INDEX OF TOPICS ECHARGE SYSTEM VOLTAGE CHECK...
  • Page 100 Runner 125 - 200 Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive terminal, measure the bat- tery voltage and turning on the vehicles lights with engine off, wait for the voltage to set at about 12 V.
  • Page 101 INDEX OF TOPICS URN SIGNALS SYSTEM CHECK...
  • Page 102 Runner 125 - 200 Turn signals system check The turn indicator circuit is powered by the electronic control unit. In the case it does not work, it is necessary to: • Check light bulbs efficiency. • With the key switch set to ON, check there is voltage on the black blue wire for the turn indicator control device.
  • Page 103 INDEX OF TOPICS USES...

  • Page 104: Fuse Table

    Runner 125 - 200 Fuses The electrical system has 4 fuses located inside the battery compartment to protect the different circuits of the system. The chart shows the position and characteristics of the fuses in the vehicle. CAUTION BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW.
  • Page 105 INDEX OF TOPICS ASHBOARD...
  • Page 106 Runner 125 - 200 Dashboard A= High-beam warning light; B= Engine oil pressure warning light; C= Turn indicator warning light; D= Low fuel warning light; E= Headlight warning lights; F= Rpm indicator; G= "Mode" Button; H= "Clock" Button; L= "Set" Button;...
  • Page 107 INDEX OF TOPICS EALED BATTERY...
  • Page 108 Runner 125 - 200 Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.
  • Page 109 INDEX OF TOPICS CHARGE BATTERY...
  • Page 110 Runner 125 - 200 Dry-charge battery COMMISSIONING A NEW DRY-CHARGED BATTERY - Remove the battery air pipe stop cap and each single cell cap. - Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an am- bient temperature not below 15°C, until it reaches the upper level indicated on the block.

  • Page 111: Battery Installation

    INDEX OF TOPICS ATTERY INSTALLATION...
  • Page 112 Runner 125 - 200 Battery installation • Remove the battery cover after undoing the 4 screws shown in the photograph. - Insert the battery connecting the bleeding tube. - Using the screwdriver, tighten up the battery terminal cables as far as they will go, placing the special Grover washer between the screw head and the cable terminal.
  • Page 113 INDEX OF TOPICS...
  • Page 114 UMP ELECTRICS CHECK...

  • Page 115: Pump Supply

    Runner 125 - 200 Pump electrics check Connect the tester positive probe to pin 4 of the connector of the fuel pump control device, and the negative probe to pin 3, making sure there is bat- tery voltage as indicated in the table.
  • Page 116 INDEX OF TOPICS...
  • Page 117 ENG VE NGINE FROM VEHICLE...
  • Page 118 Runner 125 - 200 Engine from vehicle Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo. Exhaust assy. Removal • Unscrew the 3 screws fixing the muffler to the engine crankcase and the sup- porting arm;...
  • Page 119 Runner 125 - 200 Engine from vehicle - Remove the 2 fixing screws of the brake pump. - Remove the screw fixing the brake calliper oil pipe support and move the tubes aside towards the vehicle front door so as not hinder the next re- moval operations.
  • Page 120 Runner 125 - 200 Engine from vehicle • Remove the holding springs and re- move the coolant out pipes; • Remove the holding springs and re- move the petrol pump low-pressure tube from the inlet manifold; • Move the accelerator wire from the throttle control rocking lever;...
  • Page 121 Runner 125 - 200 Engine from vehicle • Remove the holding spring and move the petrol feed pipe to carburettor; • Remove the starter cover, undo the carburettor fastening screw and re- move the pipe. • Remove the lower screws fastening the rear shock absorbers to the engine crankcase and the supporting arm;...
  • Page 122 Runner 125 - 200 Engine from vehicle • Disconnect the electric connector link- ing the magneto flywheel to the vehicle cable harness. • Remove the starter motor electrical connections operating on the two screws. • Remove the footrest and the left side fairing;...
  • Page 123 Runner 125 - 200 Engine from vehicle and remove the supporting plate from the swinging arm buffer. • Support the vehicle adequately with the jack. Remove the engine - swinging arm fixing pin operating on the nut and the pin head.
  • Page 124 INDEX OF TOPICS...
  • Page 125 NGINE...

  • Page 126: Automatic Transmission

    Runner 125 - 200 Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.

  • Page 127: Removing The Driven Pulley Shaft Bearing

    Runner 125 - 200 Engine - To remove the intake throat on the transmission cover, just remove the 3 fixing screws on the trans- mission cover. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.

  • Page 128: Removing The Driven Pulley

    Runner 125 - 200 Engine Removing the driven pulley - Remove the clutch bell housing and the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.

  • Page 129: Removing The Clutch

    Runner 125 - 200 Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft...
  • Page 130 Runner 125 - 200 Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EX-...
  • Page 131 Runner 125 - 200 Engine Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are. - Remove the retaining ring using two flat blade screwdrivers.
  • Page 132 Runner 125 - 200 Engine - Every 12,000 km, when the vehicle should be serviced according to scheduled maintenance, it is necessary to check the correct lubrication of the driven pulley roller casing. - In case the lubrication is not enough, the specific grease should be applied manually on the roller surface.

  • Page 133: Refitting The Driven Pulley

    Runner 125 - 200 Engine Refitting the driven half-pulley bearing - Support the pulley bushing adequately from the threaded side using a wooden surface. - Fit a new roller sleeve as in the figure. - For the fitting of the new ball bearing, follow the example in the figure using a modular punch.
  • Page 134 Runner 125 - 200 Engine Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 106 mm Acceptable limit after use: 101 mm Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis.

  • Page 135: Specific Tooling

    Runner 125 - 200 Engine - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the appropri- ate tool. - Preload the clutch contrast spring with a traction/...
  • Page 136 Runner 125 - 200 Engine Drive-belt During the wear checks foreseen in the scheduled maintenance services at 6,000 km; 18,000 km; etc., check that the rim bottom of the toothing does not show signs of incisions or cracking (see figure): The rim bottom of the tooth must not have incisions or cracking;...

  • Page 137: Removing The Driving Pulley

    Runner 125 - 200 Engine Removing the driving pulley Driving pulley removal - Remove the plate operating on the 3 screws. - With the appropriate tool, remove the nut with the built-in Belleville washer, the drive common to the kick-starter version, and the steel washer.
  • Page 138 Runner 125 - 200 Engine - Check the wear of the roller housings and of the belt contact surfaces on both pulley halves. - Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt.
  • Page 139 Runner 125 - 200 Engine - Correctly refit the previously removed Bendix back to its position. - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread Loctite 243 Quick Set threadlock on the thread and tighten the nut to the prescribed torque.
  • Page 140 Runner 125 - 200 Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
  • Page 141 Runner 125 - 200 Engine Removing the wheel axle - Remove the wheel axis complete with gear. - Remove the intermediate gear. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following.
  • Page 142 Runner 125 - 200 Engine Removing the wheel axle bearings Hold up the hub cover and take out the bearing. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide With the appropriate tools, remove the oil seal as shown in the figure.
  • Page 143 Runner 125 - 200 Engine With the sectional punch, remove the driven pulley shaft bearing. Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings.
  • Page 144 Runner 125 - 200 Engine Assemble the seeger ring. - Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal sur- face by means of the appropriate tool used from the 52 mm side.
  • Page 145 Runner 125 - 200 Engine - Refit the driven pulley shaft bearing with a mod- ular punch as shown in the figure. N.B. IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN- ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE.

  • Page 146: Flywheel Cover

    Runner 125 - 200 Engine Flywheel cover Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover ENG - 146...

  • Page 147: Removing The Stator

    Runner 125 - 200 Engine Removing the stator - Remove the electric terminal of the minimum oil pressure switch. - Remove the two Pick-Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure.
  • Page 148 Runner 125 - 200 Engine Flywheel and starting - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. Removing the flywheel magneto - Lock the rotation of the Flywheel using a calliper spanner.
  • Page 149 Runner 125 - 200 Engine Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut to the prescribed torque - Check that the Pick-Up air gap is between 0.34 ÷ 0.76 mm.

  • Page 150: Removing The Intake Manifold

    Runner 125 - 200 Engine Removing the intake manifold - Remove the flywheel cover completely as de- scribed in the flywheel cover section. - Loosen the 3 crews and remove the intake mani- fold. N.B. SCREWS AGAINST ACCIDENTAL OPERATION ARE PRO-...
  • Page 151 Runner 125 - 200 Engine - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure.

  • Page 152: Removing The Cam Shaft

    Runner 125 - 200 Engine - Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The chain tensioning pad must be removed from the transmission side. As regards the lower chain guide pad, it may only be removed after the head has been removed.

  • Page 153: Removing The Cylinder Head

    Runner 125 - 200 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion.
  • Page 154 Runner 125 - 200 Engine Removing the cylinder - piston assy. - Remove the chain guide pad. - Pull out the cylinder. - Remove the cylinder base gasket. - Remove the two stop rings, the wrist pin and the piston.
  • Page 155 Runner 125 - 200 Engine ENG - 155...

  • Page 156: Inspecting The Small End

    Runner 125 - 200 Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
  • Page 157 Runner 125 - 200 Engine - The cylinder surface roughness should be 0.9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consump- tion and guarantees optimum performance. For 125 engines...

  • Page 158: Inspecting The Piston

    Runner 125 - 200 Engine Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.

  • Page 159: Removing The Piston

    Runner 125 - 200 Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Fit the pin stop ring onto the appropriate tool. - With opening in the position indicated on the tool...
  • Page 160 Runner 125 - 200 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, with- out any base gasket. - Assemble a dial gauge on the specific tool Support to check piston position 020428Y - Set the dial gauge to zero placing the tool on a contrasting surface.
  • Page 161 Runner 125 - 200 Engine Refitting the piston rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.

  • Page 162: Inspecting The Cylinder Head

    Runner 125 - 200 Engine Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
  • Page 163 Runner 125 - 200 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
  • Page 164 Runner 125 - 200 Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
  • Page 165 Runner 125 - 200 Engine CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COM- POUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
  • Page 166 Runner 125 - 200 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.

  • Page 167: Inspecting The Cam Shaft

    Runner 125 - 200 Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft.
  • Page 168 Runner 125 - 200 Engine Cam shaft check: Maximum admissible axial clearance 0.42 mm Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm Cam shaft check: Standard height Outlet: 29.209 mm Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm...
  • Page 169 Runner 125 - 200 Engine Fit the pins and rocking levers. - Lubricate the two rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers.
  • Page 170 Runner 125 - 200 Engine Assemble the limiting bell using the counterweight fixing screw as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Limiting bell screw 11 ÷ 15 Nm Set the tensioner cursor to the rest position.
  • Page 171 Runner 125 - 200 Engine Name Torque in Nm Slider screw 10 ÷ 14 Nm - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head.

  • Page 172: Crankcase - Crankshaft

    Runner 125 - 200 Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
  • Page 173 Runner 125 - 200 Engine Before opening the engine crankcase, it is advis- able to check axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge. Higher clearances are signs of wear on the sup- porting surfaces of the crankshaft casing.
  • Page 174 Runner 125 - 200 Engine Fitting clearance Connecting rod axial clearance 0.20 - 0.50 Check the radial clearance on the connecting rod. Standard clearance: 0.036 ÷ 0.054 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the diagram.
  • Page 175 Runner 125 - 200 Engine Standard diameter - Category 1 28.994 ÷ 29.000 Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 176 Runner 125 - 200 Engine RANKSHAFT ALIGNMENT Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine Crankshaft alignment Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take...
  • Page 177 Runner 125 - 200 Engine - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking partic- ular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket be- tween the crankcase halves or the mating surfaces...
  • Page 178 Runner 125 - 200 Engine - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder. - To prevent obstructions in the oil feeding chan- nels, the matching surface of the two half-bearings must be perfectly perpendicular to the cylinder ax- is, as shown in the figure.
  • Page 179 Runner 125 - 200 Engine Bush- Crank- Internal bush- Possible ing cat- case ing diameter fitting egory halves after fitting category 29.025 ÷ Original 29.040 29.019 ÷ Original 29.034 and spare 29.028 ÷ 29.043 29.022 ÷ Original 29.037 Match the shaft with two category 1 crank webs with the category 1 crankcase (or cat.
  • Page 180 Runner 125 - 200 Engine Refitting the crankcase halves - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter joint and tighten it to the prescribed torque. - Fit the oil pre-filter insert into the half crankcase on the transmission side as shown in the figure.

  • Page 181: Lubrication Circuit

    Runner 125 - 200 Engine Lubrication Conceptual diagrams LUBRICATION CIRCUIT ENG - 181...
  • Page 182 Runner 125 - 200 Engine ENG - 182...

  • Page 183: Oil Pressure Check

    Runner 125 - 200 Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...

  • Page 184: Crankshaft Oil Seals

    Runner 125 - 200 Engine Crankshaft oil seals Refitting - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter joint and tighten it to the prescribed torque. - Fit the oil pre-filter insert into the half crankcase on the transmission side as shown in the figure.
  • Page 185 Runner 125 - 200 Engine Oil pump - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
  • Page 186 Runner 125 - 200 Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal.
  • Page 187 Runner 125 - 200 Engine - When testing the lubrication system, refer to chapter "Crankcase and Crankshaft", regard- ing lubrication of the crankshaft and connect- ing rod Locking torques (N*m) Oil sump screws 10 ÷ 14 SAS valve Inspecting the one-way valve - Remove the SAS valve.
  • Page 188 Runner 125 - 200 Engine 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 all the time.

  • Page 189: Removing The Carburettor

    Runner 125 - 200 Engine Removing the carburettor Kehin - To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connection, the clamps anchoring the carburettor...
  • Page 190 Runner 125 - 200 Engine - Remove the clamp and cover with the airing filter of the diaphragm chamber. - Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
  • Page 191 Runner 125 - 200 Engine - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure. - Remove the chamber with the accelerating pump, its control and gasket.
  • Page 192 Runner 125 - 200 Engine Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side. - Remove the float and the plunger. - Remove the maximum nozzle -Remove the maximum nozzle.
  • Page 193 Runner 125 - 200 Engine -Remove diffuser. - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 194 Runner 125 - 200 Engine - Remove the minimum flow set screw and the spring. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE, PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR PROGRESSIONS AND INLET NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT.
  • Page 195 Runner 125 - 200 Engine Remove the clamp and cover with the airing filter of the diaphragm chamber. Remove the 4 fixing screws indicated in the figure and the vacuum chamber cover. N.B. DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
  • Page 196 Runner 125 - 200 Engine Remove the vacuum valve together with the dia- phragm. Unscrew the bayonet joint 1/8 of a turn, remove it, take out the spring and vacuum valve plunger Remove the 4 screws shown in the figure.
  • Page 197 Runner 125 - 200 Engine Remove the tank with the intake pump, its control and gasket. Remove the acceleration pump piston with the ring nut, the hood, the O-Ring and the spring from the tank as shown in the figure.
  • Page 198 Runner 125 - 200 Engine Remove the cover of the duct from the carburettor to the starter nozzle as shown in the figure. -Remove the maximum nozzle. -Remove diffuser. ENG - 198...
  • Page 199 Runner 125 - 200 Engine Remove the sprayer. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 200 Runner 125 - 200 Engine Remove the minimum flow screw with the O-ring, the washer and the spring. -Remove the 2 fixing screws, the cover, the spring, and the cut-off device diaphragm. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE...
  • Page 201 Runner 125 - 200 Engine - For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section controlled by flow screw, progression holes near the throttle valve. - For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations.
  • Page 202 Runner 125 - 200 Engine - Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the noz- zle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser.
  • Page 203 Runner 125 - 200 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air.
  • Page 204 Runner 125 - 200 Engine Walbro - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
  • Page 205 Runner 125 - 200 Engine - For the starter circuit, blow the connection pipe properly with the jet.This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. N.B. THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
  • Page 206 Runner 125 - 200 Engine Level check Kehin - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
  • Page 207 Runner 125 - 200 Engine - Remove the drainage screw from the tank, wash and blow the tank properly and make sure the ac- celeration pump intake and supply valve are clean. - Being the valves unidirectional, blow them care-...
  • Page 208 Runner 125 - 200 Engine - Prepare the carburettor for adjustment by rotating the screw 3 turns from the close position. - Check that the rocking lever control of the accel- erating pump does not show abnormal wear. - Check that the end of stroke screw of the rocking lever protrudes 3.2 mm.
  • Page 209 Runner 125 - 200 Engine N.B. THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION. - Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover.
  • Page 210 Runner 125 - 200 Engine - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Walbro - Check that the pin does not show signs of wear and that the lock is in the 3rd of the 3 notches.
  • Page 211 Runner 125 - 200 Engine - Check that the diaphragm is not worn or has hardened. If it does, replace it. - Refit the tapered pin on the vacuum valve. - Make sure the spring is in the correct position on the plunger and inserted in its housing.
  • Page 212 Runner 125 - 200 Engine Inspecting the automatic choke device - Check that the piston of the automatic starter is not deformed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the sealing gasket of the piston is not deformed.
  • Page 213 Runner 125 - 200 Engine 5 min Electric characteristic Check the automatic starter: Resistance around 30 Ω Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support.
  • Page 214 Runner 125 - 200 Engine TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNEC- TED TO THE STARTER. Characteristic Check the automatic starter: Kehin: Protrusion value XX ÷...

  • Page 215: Adjusting The Idle

    Runner 125 - 200 Engine Characteristic Check the auto starter: Protrusion Value for Walbro 12.5 ÷ 13 mm at approx. 20°C Check the automatic starter: Walbro maximum protrusion 18.5 ÷ 19 mm Check the automatic starter: Walbro max. time 5 min...
  • Page 216 Runner 125 - 200 Engine 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.
  • Page 217 Runner 125 - 200 Engine CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 ÷ 8000 Characteristic Idle adjustment: Pipe sizes Ø 40 mm Idle adjustment: length 500 ÷- 600 mm ENG - 217...

  • Page 218: Index Of Topics

    INDEX OF TOPICS...
  • Page 219 SUSP USPENSIONS...

  • Page 220: Removing The Front Wheel

    Runner 125 - 200 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel • Remove the front brake calliper after undoing the screws fixing it to the leg. •...
  • Page 221 Runner 125 - 200 Suspensions - Remove the internal spacer - Use appropriate handle, adaptor and guide and hit with a mallet to extract the bearing and the spacer bushing on the brake disk side; insert han- dle on the side the rpm indicator detects move-...

  • Page 222: Refitting The Front Wheel

    Runner 125 - 200 Suspensions Removing the front wheel Refitting the front wheel • Check that the seal of the relative con- tact track on the wheel of the odometer transmission is in good condition. • Insert the wheel axle, after greasing it,...

  • Page 223: Front Fork

    Runner 125 - 200 Suspensions upwards, then remove the lower plastic cover. N.B. IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING, IT IS ONLY NECESSARY TO TILT THE HANDLEBAR FORWARD ONTO THE FRONT PART OF THE VEHICLE WITHOUT REMOVING THE PARTS FITTED SO AS TO AVOID DAMAGING THE SHAFTS.
  • Page 224 Runner 125 - 200 Suspensions Overhaul - With the 10 mm hexagonal wrench for internal parts loosen the upper stem closing cap. - Loosen the stem support clamp and remove fork leg and stem. - Remove the first spring featuring 15 turns.
  • Page 225 Runner 125 - 200 Suspensions - Remove the oil guard safety lock using a screw- driver. - Using the appropriate special tool, remove the oil seal. - Insert the tie rod complete with cable into the oil guard. - Insert in sequence the two half-rings per Ø 35- mm stems.
  • Page 226 Runner 125 - 200 Suspensions Check that the oil holes on the pumping element are not clogged. - Check that the O-ring shows no sign of damage. - Insert a new oil guard with the special adaptor handle and take it to the stop.
  • Page 227 Runner 125 - 200 Suspensions - Insert the 21 winding springs, the support plate with the chamfer facing downwards and then the 15 winding spring. - Insert the stem into the fork clamp. - Do up the clamp once to allow the stem closure upper cap to be tightened.

  • Page 228: Steering Bearing

    Runner 125 - 200 Suspensions - Insert the fork into the headstock. - Insert the spacer ring. - Using an appropriate tool do up the first ring nut in the steering tube (upper steering ball bearing). Lock with a torque of 10 ÷ 13 Nm and rotate the wrench anticlockwise by 90°.
  • Page 229 Runner 125 - 200 Suspensions Removal Remove upper bearing with an appropriate tool. N.B. USE THE APPROPRIATE TOOL AGAIN TO REMOVE THE LOWER HOUSING OF THE STEERING LOWER BEARING Specific tooling 020004Y Punch for removing fifth wheels from headstock SUSP - 229...
  • Page 230 Runner 125 - 200 Suspensions Refitting Insert the lower and upper bearing on the chassis using an appropriate tool. N.B. ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAME- TER. Specific tooling 001330Y Tool for fitting steering seats...

  • Page 231: Removing The Rear Wheel

    Runner 125 - 200 Suspensions Removing the rear wheel Removal - Remove the whole muffler; - Remove the shock absorber - wheel supporting bracket; - Remove the 5 screws fixing the wheel and re- move it; Reassembly Carry out the previous operations in reverse order.
  • Page 232 Runner 125 - 200 Suspensions - Check the entire swinging arm assembly. - Check all the centring bushing components and silent block rubber buffers. - Replace the work components that cause exces- sive clearance on the rear suspension. Overhaul - Make sure the silent bloc is not broken. If there is, replace it.
  • Page 233 Runner 125 - 200 Suspensions - Remove the full silent bloc bracket - Undo the silent bloc ring shown in the photograph - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle.
  • Page 234 Runner 125 - 200 Suspensions - Using the appropriate tool, fit the silent bloc as shown in the photo - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side.
  • Page 235 Runner 125 - 200 Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the plastic bushings and the internal spacer shown in the photo. - Using a suitable pin remove the roller casings as...

  • Page 236: Shock Absorbers

    Runner 125 - 200 Suspensions Length of the swinging arm tube on the frame side: 283 ± 0.1 mm - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in...
  • Page 237 Runner 125 - 200 Suspensions Refitting Carry out the previous operations but in reverse order. Locking torques (N*m) Lower shock absorber clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41 Exhaust bracket Removal Remove the full muffler unit.

  • Page 238: Centre-Stand

    Runner 125 - 200 Suspensions Refitting - The refitting procedure is in the reverse order of the removal operation being careful to respect the torques indicated and the spacer assembly layout as shown in the photo. Locking torques (N*m) Bracket fixing screws to the engine crank-...

  • Page 239: Index Of Topics

    INDEX OF TOPICS...

  • Page 240: Braking System

    BRAK SYS RAKING SYSTEM...

  • Page 242: Rear Brake Calliper

    Runner 125 - 200 Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the rear wheel. - Remove the pad retention pin snap ring. - Using a pin partially remove the brake pad re- tention pin.
  • Page 243 Runner 125 - 200 Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to...

  • Page 244: Front Brake Calliper

    Runner 125 - 200 Braking system - Keep the brake pads in contact with the pistons and insert the calliper in the brake disc. - Fix the calliper to the crankcase with the two screws with elastic washer at the prescribed tor-...
  • Page 245 Runner 125 - 200 Braking system Removal - Place a suitable container to collect the oil and disconnect the oil pipe from the calliper operating the joint. - Remove the two screws (shown in picture) fixing the calliper to the fork and remove the fork.
  • Page 246 Runner 125 - 200 Braking system and then the pads, fixing them with the corre- sponding screws (1); 5) place the calliper on the disc and lock it to the strut by tightening the fixing screws; 6) fix the pipe joint on the calliper at the prescribed torque.

  • Page 247: Rear Brake Disc

    Runner 125 - 200 Braking system Refitting Insert the following on the front brake body: -The sealing rings and the pistons (1). -Refit the plate (2). - Arrange the pad holding clamp (3). -Refit the pads and bleed air. -Place the calliper on the disk and lock it to the support by tightening the bolts at the prescribed torque.

  • Page 248: Disc Inspection

    Runner 125 - 200 Braking system Disk to the hub 11 ÷ 13 Disc Inspection - Remove the rear brake calliper. - Check the disc thickness with a micrometer Characteristic Minimum thickness allowed after use: 3.5 mm Standard thickness: 4 +0.2-0.2 mm - Repeat the measurement at no fewer than six points on the disc.
  • Page 249 Runner 125 - 200 Braking system Removal - Remove the front wheel - Remove the disk from the front wheel operating the 6 screws. Refitting - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.

  • Page 250: Front Brake Pads

    Runner 125 - 200 Braking system Characteristic Standard thickness: 4 +0.2-0.2 mm Max. deviation allowed: 0.1 mm Front brake pads Removal - Preloosen the two fixing pins of the brake pads - Remove the brake calliper - Remove permanently the two pad fixing screws - Check that there are no flaws or warping.

  • Page 251: Rear Brake Pads

    Runner 125 - 200 Braking system Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
  • Page 252 Runner 125 - 200 Braking system See also Removal Refitting - Insert the brake pads - Insert the fixing pin being careful to position the clip with the ends towards the bleed screw as in the photo. - Insert the clip on the pin - Fix the rear brake calliper to the bracket and tighten the two screws to the specified torque.
  • Page 253 Runner 125 - 200 Braking system Fill Front - Rest the scooter on its stand on level ground. - Remove the front handlebar cover. - Remove the brake pump cover unscrewing the two screws. - Refill the brake system tank up to the maximum level with the prescribed fluid.
  • Page 254 Runner 125 - 200 Braking system Overhaul 1) Remove the brake lever by loosening the fixing screw; open the cover (2) and take out the diaphragm (3); 2) Remove the cap and unscrew the internal parts in the specified order;...
  • Page 255 Runner 125 - 200 Braking system 6. Piston. 7. Gasket. 8. Spring. BRAK SYS - 255...

  • Page 256: Index Of Topics

    INDEX OF TOPICS...

  • Page 257: Cooling System

    COOL SYS OOLING SYSTEM...

  • Page 259: Circuit Diagram

    Runner 125 - 200 Cooling system Questa sezione è in lavorazione. Circuit diagram COOL SYS - 259...
  • Page 260 Runner 125 - 200 Cooling system Water pump - overhaul With a hot air gun heat the flywheel cover on the inner side. - Place the flywheel cover on the ring base follow- ing the same procedure as for removal.
  • Page 261 Runner 125 - 200 Cooling system N.B. DO NOT LUBRICATE THE O-RING. FAILURE TO RESPECT THIS RULE RESULTS IN RING DISTORTION. Specific tooling 020440Y Water pump service tool Locking torques (N*m) Water pump rotor cover 3 ÷ 4 Water pump ceramic seal Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the ceramic seal in the subject.
  • Page 262 Runner 125 - 200 Cooling system such cases we recommend cleaning the casing in order to be able to check again for leaks after a distance of more than 1500 km. If leaks continue or in the event of real losses, the ceramic seal should be replaced.
  • Page 263 Runner 125 - 200 Cooling system Check components - Check that the rotor does not show abnormal wear or dents; - Check that the rotor shaft is not rusty; - Check that there is no rust on the bearing seats or the ceramic seal;...
  • Page 264 Runner 125 - 200 Cooling system Removal - Loosen the two screws indicated in the figure and remove the thermostat cover. - Remove the thermostat with its gasket. Check - Visually check that the thermostat is not dam- aged. - Prepare a metal container with approx. 1 litre of water.
  • Page 265 Runner 125 - 200 Cooling system 1) Look to see that the thermostat is not damaged. 2) Fill a metal container with approx. 1 litre of wa- ter. Immerse the thermostat, and keep it in the centre of the container.
  • Page 266 INDEX OF TOPICS...
  • Page 267 CHAS HASSIS...
  • Page 269 Runner 125 - 200 Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat Lift the saddle and remove the screws indicated in the photograph Rear handlebar cover - Remove the front handlebar cover...
  • Page 270 Runner 125 - 200 Chassis Front handlebar cover -Remove the rear-view mirrors. -Remove the two screws shown in the figure, and at the same time disconnect the fitting in the upper part of the handlebar cover. Pull the front part up- wards so as not to damage the fittings made of plastic.
  • Page 271 Runner 125 - 200 Chassis - Remove the ring nut of the fuel tank cap by un- screwing the 3 screws indicated in the photograph. - Remove the filling hole unit of the fuel tank by loosening the 3 screws <A> indicated in the pho- tograph and the metal clamp.
  • Page 272 Runner 125 - 200 Chassis - Remove the front shield after disconnecting the wiring of the front headlight assembly and of the taillights. Assembly following the procedure in reverse or- der. See also Front central cover Knee-guard - Remove the central chassis cover.
  • Page 273 Runner 125 - 200 Chassis Front central cover Removing the ignition key-switch when on *off* - Remove the shield back plate. - Remove the immobilizer aerial as shown in the figure. - Detach the electrical wiring. - Remove the ignition key-switch, by removing the spring retainer shown in the figure.
  • Page 274 Runner 125 - 200 Chassis - Lightly push the master-cylinder and extract the lock from the notch shown in the figure. - Hence extract the master-cylinder complete with the key-switch. - For the reassembly proceed in the reverse order. Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the...
  • Page 275 Runner 125 - 200 Chassis Taillight assy. Remove the two screws and take out the whole unit. Footrest Remove the 3 screws indicated in the figure and remove the footrest. CHAS - 275...
  • Page 276 Runner 125 - 200 Chassis Side fairings The side fairing consists of 3 parts as described in the figure. Fairing A - Remove the 4 screws indicated in the figure and take out the casing. Fairing B - Remove fairing A - Remove the passenger handles.
  • Page 277 Runner 125 - 200 Chassis Fairing C - Remove the central chassis cover. - Remove the lateral fairings A and B. - Remove the fairing by pulling it upwards. Air filter - Undo the three screws fixing the housing to the engine crankcase;...
  • Page 278 Runner 125 - 200 Chassis Helmet bay - Remove the battery after disconnecting the wir- ing. - Remove the saddle. - Remove the rear central cover. - Remove the side panels - Remove the wiring found in the battery compart- ment.

  • Page 279: Front Mudguard

    Runner 125 - 200 Chassis Fuel tank - Remove the central chassis cover. Remove the side fairings and the helmet compart- ment. - Remove the screw <C> indicated in the figure at both sides. - Remove the bolt <A> and loosen the nut <B>in- dicated in the figure.

  • Page 280: Expansion Tank

    Runner 125 - 200 Chassis Expansion tank - Remove the front shield. Remove the screw indicated in the photograph. - Remove the cap momentarily to disconnect it from the shield back plate by pulling it downwards. - Disconnect the expansion tank from the support anchored to the chassis.
  • Page 281 Runner 125 - 200 Chassis CHAS - 281...

  • Page 282: Index Of Topics

    INDEX OF TOPICS...
  • Page 283 PRE DE DELIVERY...
  • Page 285 Runner 125 - 200 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check...
  • Page 286 Runner 125 - 200 Pre-delivery - Horn - Starter 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.

  • Page 287: Static Test

    Runner 125 - 200 Pre-delivery - Abnormal noise Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 288 INDEX OF TOPICS...
  • Page 289 TIME...
  • Page 291 Runner 125 - 200 Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine NGINE Code Action Duration 001001 Engine - Replacement 001136 Exhaust emissions - Adjustment...
  • Page 292 Runner 125 - 200 Time Crankcase RANKCASE Code Action Duration 001153 Crankcase gasket - Replacement 001133 Engine crankcase- Replacement TIME - 292...
  • Page 293 Runner 125 - 200 Time Crankshaft RANKSHAFT Code Action Duration 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement 001100 Oil seal, clutch side - Replacement TIME - 293...

  • Page 294: Cylinder Assy

    Runner 125 - 200 Time Cylinder assy. YLINDER UNIT ISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001176 Rings / Pin - Replacement TIME - 294...

  • Page 295: Cylinder Head Assy

    Runner 125 - 200 Time Cylinder head assy. YLINDER HEAD ASSEMBLY Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 007009 Cylinder / pump rubber coupling - Re- placement...
  • Page 296 Runner 125 - 200 Time Rocker arms support assy. OCKING LEVER UNIT Code Action Duration 001148 Rocking lever valve - Replacement 001044 Camshaft - Replacement 001169 Decompressor - Replacement TIME - 296...

  • Page 297: Cylinder Head Cover

    Runner 125 - 200 Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment TIME - 297...

  • Page 298: Chain Tensioner

    Runner 125 - 200 Time Chain tensioner HAIN TIGHTENER Code Action Duration 001124 Lubrication by-pass - Replacement 001129 Chain tightener - Replacement TIME - 298...

  • Page 299: Oil Filter

    Runner 125 - 200 Time Oil filter IL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Replacement 001102 Oil mesh filter - Change / Cleaning TIME - 299...

  • Page 300: Driven Pulley

    Runner 125 - 200 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement TIME - 300...

  • Page 301: Oil Pump

    Runner 125 - 200 Time Oil pump OIL PUMP Code Action Duration 001125 Chain guide sliders - Replacement 001051 Distribution belt - chain - Replace- ment 001042 Oil pump - Service 001112 Oil pump - Replacement 001122 Oil pump chain...

  • Page 302: Final Reduction

    Runner 125 - 200 Time Final gear assy. FINAL REDUCTION Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Re- placement 004125 Rear wheel axle - Replacement TIME - 302...

  • Page 303: Driving Pulley

    Runner 125 - 200 Time Driving pulley RIVING PULLEY REPAIR TIME Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001006 rear-view pulley - Service 001066 driving pulley - Replacement 001177 Variator rollers / shoes - Replace-...
  • Page 304 Runner 125 - 200 Time Transmission cover RANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001135 Transmission cover bearing - Re- placement 001170 Air deflector - Replacement TIME - 304...

  • Page 305: Starter Motor

    Runner 125 - 200 Time Starter motor TARTER MOTOR Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement 001141 Belt anti-flapping roller - Replace- ment 001175 Anti-vibration roller - Service 005045 Starter motor cable assembly - Re-...

  • Page 306: Flywheel Magneto

    Runner 125 - 200 Time Flywheel magneto AGNETO FLYWHEEL AND SECONDARY AIR Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump / Pump rotor - Replace- ment 001058 Flywheel - Replacement 001173 Rotor - Replacement 001067 Stator - Replacement...
  • Page 307 Runner 125 - 200 Time Belt cooling duct ELT COOLING TUBE Code Action Duration 001131 Transmission air inlet - Replacement 001132 Transmission air inlet tube - Replace- ment TIME - 307...
  • Page 308 Runner 125 - 200 Time Carburettor ARBURETTOR Code Action Duration 001013 Intake manifold - Replacement 001081 Automatic choke - Replacement 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heating tubing - replace- ment 003058 Carburettor - Adjustment TIME - 308...

  • Page 309: Exhaust Pipe

    Runner 125 - 200 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 309...

  • Page 310: Air Cleaner

    Runner 125 - 200 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement TIME - 310...
  • Page 311 Runner 125 - 200 Time Frame HASSIS Code Action Duration 004001 Frame - replace 004116 Rear frame - Replacement 004015 Footrest - Replacement TIME - 311...
  • Page 312 Runner 125 - 200 Time Centre-stand TAND REPAIR TIME Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 001053 Stand bolt - Replacement TIME - 312...
  • Page 313 Runner 125 - 200 Time Legshield spoiler RONT SHIELD Code Action Duration 004064 Front shield - Replacement 004053 Spoiler - Replacement 004182 Side cover - Replacement 004149 Shield central cover - Replacement TIME - 313...

  • Page 314: Rear Cover

    Runner 125 - 200 Time Side fairings SIDE COVERS Code Action Duration 004057 Taillight lower cover - Replacement 004068 Passenger handgrip - Replacement 004012 Rear fairings - Removal and refitting 004129 Rear fairing - Replacement 004085 Fairing (1) - Replacement...
  • Page 315 Runner 125 - 200 Time Central cover CENTRAL COVER Code Action Duration 004011 Central chassis cover - Replace- ment 004135 Fuel tank lid - Replacement Mudguard MUDGUARD Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement...

  • Page 316: Rear Shock Absorber

    Runner 125 - 200 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Replacement Handlebar covers ANDLEBAR COVERS Code Action Duration 004019 Handlebar rear section - Replace- ment 004028 Windshield glass - Replacement 004018 Handlebar front section - Replace-...

  • Page 317: Handlebar Components

    Runner 125 - 200 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002063 Throttle control transmission - Re- placement 003061 Accelerator transmission - Adjust- ment 003059 Counterweight - Replacement 005017 Stop switch - Replacement 002024 Front brake pump - Replacement...

  • Page 318: Instrument Panel

    Runner 125 - 200 Time WINGING ARM Code Action Duration 003081 Swinging arm supporting flange - Re- placement 004058 Silent-block - Replacement 001072 Engine/frame swinging arm attach- ment - Replacement Seat SADDLE Code Action Duration 004003 Saddle - Replacement Instrument panel...

  • Page 319: Turn Signal Lights

    Runner 125 - 200 Time Locks LOCKS Code Action Duration 004010 Anti-theft lock - Replacement 005016 Key switch - Replacement 004054 Saddle lock catch - Replacement Turn signal lights Fanaleria posteriore EAR LIGHTS Code Action Duration 005005 Taillight - Re-...

  • Page 320: Front Wheel

    Runner 125 - 200 Time NDICATOR LIGHTS Code Action Duration 005002 Front light - Replacement 005008 Headlight bulbs - Replacement 005012 Front direction indicators - Replace- ment 005067 Front turn indicator bulb - Replace- ment Front wheel RONT WHEEL Code...

  • Page 321: Fuel Pump

    Runner 125 - 200 Time Code Action Duration 001071 Rear wheel rim - Replacement 004126 Rear wheel tyre - Replacement 002070 Rear brake disc - Replacement 003077 muffler/rear shock absorber support arm - Service Fuel pump UEL PUMP Code Action...

  • Page 322: Electric Devices

    Runner 125 - 200 Time Electric devices LECTRICAL DEVICES Code Action Duration 005001 Electrical system - Replacement 005114 Electrical system - Service 005003 Horn - Replacement 001069 HV coil - replace 001023 Control unit - Replacement 005035 Headlight remote control - Replace-...
  • Page 323 Runner 125 - 200 Time Rear side fairings EAR COVERS Code Action Duration 004056 Upper rear light cover - Replacement 004136 License plate support - Replacement 004183 Cover for engine components - Re- placement 004181 Lower cover - Replacement 005048...

  • Page 324: Front Suspension

    Runner 125 - 200 Time Front suspension RONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering thrust washer - Replace-...

  • Page 325: Cooling System

    Runner 125 - 200 Time Cooling system OOLING SYSTEM Code Action Duration 007002 Water radiator - replacement 007016 Fan with support - Replacement 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007019 Connection water pump pipe / return...

  • Page 326: Braking System

    Runner 125 - 200 Time Braking system RAKE SYSTEM Code Action Duration 002007 Front brake pads - Replacement 002039 Front brake calliper - Replacement 002021 Front brake piping - Replacement 002002 Rear brake pads - Replacement 002048 Rear brake calliper - Replacement...
  • Page 327 Air filter: 44, 277 Battery: 58, 70, 94, 108, 110, 112 Brake: 242, 244, 247, 248, 250, 251, 253 Carburettor: 12, 38, 189, 200, 308 Engine oil: 44 Engine stop: Fuel: 57, 279, 315, 321 Fuses: 104 Headlight: 49, 270 Hub oil: 42 Identification: 9 Instrument panel: 318...

This manual is also suitable for:

Runner 200

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