Table Of Contents - Derbi GP1 50 cc Workshop Manual

Table of Contents

Introduction2
Contents4
General Information9
Safety Regulations9
Maintenance Regulations9
General Technical Data10
Dimensions And Weight10
Engine10
Transmission11
Capacity11
Electrical System11
Frame And Suspensions12
Braking System12
Wheels And Tyres12
Carburettor12
Chassis Tightening Torques14
Engine Tightening Torques15
Connection Piston And Cylinder16
Piston Rings16
End Play Between Crankcase, Crankshaft And Connecting Rod17
Slot Packing System17
Recommended Tools19
Preparation For Removal And Dismantling19
Replacement Parts20
Seals, Retaining Rings And O-Rings20
Tab/Spacer Washers And Split Pins20
Bearings And Retaining Rings20
Locking Rings21
Special Tools21
Periodic Maintenance25
Maintenance Chart25
Spark Plug30
Hub Oil31
Check31
Replacement31
Characteristic31
Air Filter32
Checking The Ignition Timing33
Headlight Adjustment35
Dismantling36
Seat Side Trim36
Cowling36
Lower Cowling Cover37
Water-Oil Cover37
Side Covers37
Shield Inner Cover38
Petrol Tank Cover38
Helmet Carrier39
Footrests40
Shield40
Direct Access To The Bottom Of The Carburettor41
Dismantling Footrests/Extracting Complete Filter Box41
Disconnect The Secondary Air Pipe41
Extract Carburettor Air Inlet Pipe41
Extract Carburettor42
Dismantling The Machine's Engine44
Automatic Transmission44
Removing The Driven Pulley Shaft Bearing45
Refitting The Driven Pulley Shaft Bearing45
Removing The Driven Pulley46
Inspecting The Clutch Drum46
Removing The Clutch46
Inspecting The Clutch47
Pin Retaining Collar47
Removing The Driven Half-Pulley Bearing48
Inspecting The Driven Fixed Half Pulley48
Inspecting The Driven Sliding Half Pulley49
Refitting The Driven Half-Pulley Bearing50
Inspecting The Clutch Spring50
Refitting The Clutch50
Refitting The Driven Pulley51
Drive Belt51
Removing The Driving Pulley52
Mixer Gears And Belt52
Inspecting The Rollers Case52
Refitting The Driving Pulley53
Dismantling Engine Pinion54
Removing The Hub Cover54
Dismantling Output Pinion Shaft Bearing55
Inspecting The Hub Shaft56
Inspecting The Hub Cover56
Refitting The Wheel Axle Bearing57
Refitting The Ub Cover58
Flywheel Cover58
Removing The Stator58
Refitting The Stator58
Refitting The Flywheel Cover59
Flywheel And Starting59
Removing The Starter Motor59
Removing The Flywheel Magneto59
Inspecting The Flywheel Components60
Refitting The Flywheel Magneto60
Refitting The Starter Motor61
Cylinder Assy. And Timing System61
Removing The Intake Manifold61
Removing The Cylinder Head61
Removing The Cylinder-Piston Assy62
Inspecting The Small End62
Inspecting The Wrist Pin62
Inspecting The Piston63
Inspecting The Cylinder63
Inspecting The Piston Rings64
Removing The Piston64
Inspecting The Timing System Components65
Crankcase - Crankshaft66
Splitting The Crankcase Halves66
Removing The Crankshaft Bearings66
Refitting The Crankshaft Bearings67
Inspecting The Crankshaft Alignment68
Refitting The Crankshaft68
Refitting The Crankcase Halves69
Lubrication70
Crankshaft Oil Seals70
Oil Pump71
Removal71
Refitting71
Fuel Supply72
Forks73
Sebac Forks73
Marzocchi Forks74
Dismantling Front Suspension75
Inspecting The Front Forks77
Shock Absorber And Swinging Arm79
Front Wheel And Brake81
Front Wheel Diagram81
Inspecting The Front Wheel82
Dismantling The Front Disk Calliper84
Fitting The Front Calliper84
Extracting The Front Brake Pads85
Fitting The Front Brake Pads85
Inspecting The Pads For Wear85
Extracting The Front Brake Cylinder85
Fitting The Front Master Cylinder86
Checking The Brake Calliper Main Cylinder87
Extracting The Brake Disk87
Fitting The Brake Disk87
Wear To The Brake Disk87
Brake Disk Distortion88
Disk Deviation From Centre88
Bleeding The Brake System Pipe88
Fit89
Assembling The Front Wheel90
Wheel Diagram92
Dismantling The Rear Disk Calliper93
Fitting The Rear Calliper94
Extracting The Rear Brake Pads94
Fitting The Rear Brake Pads94
Rear Wheel And Brakes95
Extracting The Rear Main Cylinder95
Fitting The Rear Main Cylinder95
Checking The Rear Main Cylinder (Visual Check)96
Checking The Rear Calliper Main Cylinder96
Brake Disk Wear97
Inspecting The Rear Wheel100
Fitting The Rear Wheel100
Transmision Chain100
Inspecting The Drive Chain102
Chain Sprocket102
Fitting The Chain Sprocket And The Drive Chain103
Cooling System104
System Bleed104
Water Pump-Overhaul104
Thermostat107
Gp1 50 C.c. Wiring Diagram109
Switzerland110
Checking Connectors111
Inspection Steps112
Digital Instruments Unit112
Ignition113
Automatic Choke And Lights114
Battery Recharge And Starting115
Level Indicators116
Turn Indicators And Horn117
Checks And Inspections118
Checking The Pick Up118
Checking The Recharge Coil118
Ignition Circuit119
Stator Check119
Voltage Regulator Check119
Interventions120
Fuses123
Dismantling The Battery123
Filling With Electrolyte123
Battery-Initial Charge125
Interchangeability126
Inspecting The Charging Conditions126
Recharging127
Charging System128
Standard Values To Determine The State Of The Battery128
Standard Battery Charging Time128
Monitoring Graph To Determine Battery Condition128
Troubleshooting129
Poor Performance129
Rear Wheel Spins At Idle130
Starting Difficulty130
Excessive Oil Consumption/Exhaust Smoke131
Engine Tends To Cut-Off At Full Throttle/At Idle131
Engine Stops At Full Throttle/At Idle131
High Fuel Consumption132
Excessive Consumption/Exhaust Noise132
Noise Increase132
Engine Overheating132
Sas Malfunctions133
Looseness Of Rubber Union Of Secondary Air Tube To Silencer133
Transmission And Brakes - Clutch Grabbing Or Performing Inadequately133
Insufficient Braking134
Braking System Failure134
Brakes Overheating134
Battery135
Steering And Suspensions - Rear Wheel135
Poor Road Handling135
Heavy Steering136
Excessive Steering Play136
Noisy Suspension136
Suspension Oil Leakage137