PIAGGIO Carnaby 125 Service Station Manual
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PIAGGIO Carnaby 125 Service Station Manual

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SERVICE STATION MANUAL
633986 IT-633987 EN-633988 FR-633989 DE-633990
ES-633991 PT-633992 OL-633993 EL
Carnaby 125 - 200

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Summary of Contents for PIAGGIO Carnaby 125

  • Page 1 SERVICE STATION MANUAL 633986 IT-633987 EN-633988 FR-633989 DE-633990 ES-633991 PT-633992 OL-633993 EL Carnaby 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 SERVICE STATION MANUAL Carnaby 125 - 200 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle repairing techniques and procedures.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: 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 8: Vehicle Identification

    Carnaby 125 - 200 Characteristics Vehicle identification The chassis prefix «A» is located near the right shock absorber connection to the frame. The engine prefix «B» is stamped near the left shock absorber lower support. VEHICLE IDENTIFICATION 125 Specification Desc./Quantity...
  • Page 9 Carnaby 125 - 200 Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS 125 Specification Desc./Quantity Kerb weight 154 ± 5 kg Maximum weight allowed 350 kg Overall height 1.175 mm Width 755 mm Wheelbase 1.370 mm Length 2,025 mm WEIGHTS AND DIMENSIONS 200 Specification Desc./Quantity...

  • Page 10: Electrical System

    Carnaby 125 - 200 Characteristics Specification Desc./Quantity Lubrication Engine lubrication with lobe pump (inside crankcase) controlled by a chain with double filter: mesh and paper. Lubrication pressure 4 bar Minimum lubrication pressure (100° C) 0.8 bar Fuel supply KEIHIN CVEK 30 carburettor and electrical fuel pump.

  • Page 11: Wheels And Tyres

    Carnaby 125 - 200 Characteristics Specification Desc./Quantity Spark plug CHAMPION RG4HC Alternative spark plug NGK CR8EB Battery Sealed, 12 V / 10 Ah ELECTRICAL SYSTEM 200 Specification Desc./Quantity Start-up Electric Ignition Capacitive discharge ignition, with variable advance and sep- arate HV coil.
  • Page 12 Carnaby 125 - 200 Characteristics instead of entering through the muffler as for 2T engine, the secondary air enters directly in the discharge pipe on the head. The 2T reed valve has a diaphragm. The unit, indicated by an arrow in the figure, has a cut-off connected to the depression intake on the inlet manifold that cuts the air inlet in deceleration, to avoid explosions in the muffler.
  • Page 13 Carnaby 125 - 200 Characteristics The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter, thus favouring an improved reac- tion of the catalytic converter.

  • Page 14: Tightening Torques

    Carnaby 125 - 200 Characteristics Specification Desc./Quantity Tapered pin stamping 306D CUT-OFF device Not present Diffuser Ø 29 Maximum jet Minimum jet Max. air jet Minimum air jet Throttle valve spring 100 ÷ 160 g Minimum mixture set screw initial opening Tapered pin Ø...

  • Page 15: Front Suspension

    Carnaby 125 - 200 Characteristics FRONT SUSPENSION Name Torque in Nm Fixing screw for pumping elements to lower fork plate 20 ÷ 25 Front wheel axle 45 ÷ 50 Fork leg screw 6 ÷ 7 front mudguard to plate fixing screw 4.5 ÷...

  • Page 16: Cylinder Head

    Carnaby 125 - 200 Characteristics CYLINDER HEAD Name Torque in Nm Spark plug 12 ÷ 14 Nuts fixing head to cylinder (1) (^) 9 ÷ 11 + 180° Head fixing side screws 11 ÷ 12 Starter ground screw 7 ÷ 8.5 M5 side screw locking washers on camshaft 7 ÷...

  • Page 17: Assembly Clearances

    Carnaby 125 - 200 Characteristics Assembly clearances Cylinder - piston assy. 200 cm³ version COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER) 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 ÷...
  • Page 18 Carnaby 125 - 200 Characteristics 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 ÷ 56.966 0.045 - 0.059...
  • Page 19 Carnaby 125 - 200 Characteristics ENGINE SEALING RINGS 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 ENGINE SEALING RINGS (1ST OVERSIZE)
  • Page 20 Carnaby 125 - 200 Characteristics ENGINE SEALING RINGS Name Description Dimensions Initials Quantity Compression ring 72x1.5 0.15 ÷ 0.30 Oil scraper ring 72 x 1 0.10 ÷ 0.40 Oil scraper ring 72 x 2.5 0.20 ÷ 0.40 Crankcase - crankshaft - connecting rod...
  • Page 21 Carnaby 125 - 200 Characteristics Fitting clearances Crankshaft/crankcase axial clearance (H): 0.15 ÷ 0.40 mm (when cold) CHAR - 21...
  • Page 22 Carnaby 125 - 200 Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05...
  • Page 23 Carnaby 125 - 200 Characteristics Name Measure A Thickness Shimming - Cylinder 67 - Head gasket 1.1 2.45 ÷ 2.70 0.6 ± 0.05 - Base gasket 0.6 Characteristic Compression ratio 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.
  • Page 24 Carnaby 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 Oil to lubricate flexible transmissions...
  • Page 25 INDEX OF TOPICS TOOL OOLING...
  • Page 26 Carnaby 125 - 200 Tooling APPROPRIATE TOOLS 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 - 26...
  • Page 27 Carnaby 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 - 27...
  • Page 28 Carnaby 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 - 28...
  • Page 29 Carnaby 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 30 Carnaby 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 31 Carnaby 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 - 31...
  • Page 32 Carnaby 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 - 32...
  • Page 33 Carnaby 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 34 Carnaby 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 - 34...
  • Page 35 Carnaby 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 36 Carnaby 125 - 200 Tooling Stores code Description 001467Y013 Pliers to extract ø 15-mm bearings 020444Y010 adapter ring 020244Y 15 mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc 020627Y Flywheel lock wrench TOOL - 36...
  • Page 37 Carnaby 125 - 200 Tooling Stores code Description 020467Y Flywheel extractor 020626Y Driving pulley lock wrench TOOL - 37...
  • Page 38 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 39: Maintenance Chart

    Carnaby 125 - 200 Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - change Brake fluid - change EVERY 3,000 KM Action Engine oil - level check/ top-up 1,000 FTER Action Engine oil - replacement Hub oil - change Engine oil - change...
  • Page 40 Carnaby 125 - 200 Maintenance Action Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test Driving belt - replacement (*) See instructions in «Idle speed adjustment» section...
  • Page 41 Carnaby 125 - 200 Maintenance Action Vehicle and brake test - road test Engine oil - replacement Oil filter -Replacement 36,000 FTER Action Engine oil - replacement Hub oil level - check Spark plugs - replacement Air filter - clean...

  • Page 42: Checking The Spark Advance

    Carnaby 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 condition.
  • Page 43 Carnaby 125 - 200 Maintenance - The brand new control unit prevents that the engine rotation exceeds 2000 rpm. - The programmed control unit allows the engine to rotate within the prescribed limits. Specific tooling 020330Y Stroboscopic light to check timing Spark advance variation 125 cm³...

  • Page 44: Spark Plug

    Carnaby 125 - 200 Maintenance Specification Desc./Quantity Spark elimination First threshold : 1 spark on 7 Second threshold : 2 sparks on 3 Spark plug To remove the spark plug, proceed as follows: - Undo the two screws « A» and remove the cover.
  • Page 45 Carnaby 125 - 200 Maintenance - Operating on both sides of the scooter, undo the screws «B». - Remove the inspection cover «C» by pulling it upwards. - Disconnect the cap «D» from the spark plug HV wire. - Unscrew the spark plug using the wrench sup- plied.
  • Page 46 Carnaby 125 - 200 Maintenance Spark plug 12 ÷ 14 When refitting, place the spark plug into the hole at the due inclination and tighten it manually all the way down. Use the wrench only to tighten it. Once locked, insert the cap «D» on the spark plug. Refit the covers.

  • Page 47: Air Filter

    Carnaby 125 - 200 Maintenance - Unscrew the oil drainage plug "B" and drain out all the oil. - Screw the drainage plug again to the prescribed torque and refill the hub with the recommended oil. Recommended products AGIP ROTRA 80W-90 rear oil hub...

  • Page 48: Engine Oil

    Carnaby 125 - 200 Maintenance NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WILL RESULT IN AN EXCESSIVE CYLINDER AND PISTON WEAR AND ALSO IN CARBURETTOR DAMAGE. CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

  • Page 49: Engine Oil Filter

    Carnaby 125 - 200 Maintenance oil filter Check In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period.

  • Page 50: Checking The Ignition Timing

    Carnaby 125 - 200 Maintenance Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications Oil pressure warning light The vehicle is equipped with a warning light «F»...

  • Page 51: Checking The Valve Clearance

    Carnaby 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 set screw corre- sponds with the indicated values.

  • Page 52: Braking System

    Carnaby 125 - 200 Maintenance Top-up Check coolant level when the engine is cold as in- dicated in the scheduled maintenance table, fol- lowing the steps below. Place the scooter on its centre stand and on flat ground. - Undo the screw and remove the expansion tank cap located on the scooter left side.

  • Page 53: Recommended Products

    Carnaby 125 - 200 Maintenance Top-up - Remove the cover on the handlebar shown in the photograph by undoing the screw. - Remove the tank cap by loosening the two screws, remove the gasket and top up using only the liquid specified without exceeding the maxi- mum level.

  • Page 54: Headlight Adjustment

    Carnaby 125 - 200 Maintenance Headlight adjustment Proceed as follows: - Position the unloaded scooter, in running order and with the tyres inflated to the prescribed pres- sure, onto a flat surface 10 m away from a half-lit white screen; make sure the scooter axis is per- pendicular to the screen;...
  • Page 55 Carnaby 125 - 200 Maintenance - Check that the SAS valve plastic support is not dented or distorted - Check that the gasket is in good conditions - Carefully clean the inside and outside filters. Re- place them if damaged or abnormally distorted.
  • Page 56 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 57: Troubleshooting

    Carnaby 125 - 200 Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re- place Excess of encrustations in the combustion chamber...
  • Page 58 Carnaby 125 - 200 Troubleshooting Possible Cause Operation The carburettor is dirty; fuel pump damaged Remove, wash with solvent and dry with compressed air or re- place Battery flat Check the charge of the battery, if there are any sulphur marks,...

  • Page 59: Engine Overheating

    Carnaby 125 - 200 Troubleshooting Possible Cause Operation The starter remains on Check: electric wiring, circuit not interrupted, mechanical movement and power supply; replace if necessary Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air Excessive exhaust noise...
  • Page 60 Carnaby 125 - 200 Troubleshooting Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Faulty clutch Check that there is no grease on the masses. Check that the clutch mass contact surface with the casing is mainly in the centre with equivalent characteristics on the three masses.

  • Page 61: Noisy Suspension

    Carnaby 125 - 200 Troubleshooting Possible Cause Operation not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of 3 months. If the battery is fitted on a motorcycle,...
  • Page 62 Carnaby 125 - 200 Troubleshooting Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Seal fault or breakage Check the sealing conditions of the oil seals. TROUBL - 62...
  • Page 63 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 64 Carnaby 125 - 200 Electrical system 1. Electronic ignition device 2. Engine stop switch 3. Magneto flywheel - Pick-up 4. Voltage regulator 5. Fuse unit 6. Automatic starter 7. Key switch 8. Stop light remote control 9. Stop button on front brake 10.
  • Page 65 Carnaby 125 - 200 Electrical system 20. Rear light A. Tail light bulbs B. Stop light bulbs 21. Rear right turn indicator light 22. Front left turn indicator light 23. Headlight A. Tail light bulbs B. High-beam light bulb C. Low-beam light bulb 24.
  • Page 66 Carnaby 125 - 200 Electrical system LEGENDA 1. Dispositivo di accensione elettronica 2. Deviatore arresto motore 3. Volano magnete - Pick-up 4. Regolatore di tensione 5. Gruppo fusibili 6. Starter automatico 7. Commutatore a chiave 8. Teleruttore luci stop 9. Pulsante di stop sul freno anteriore 10.
  • Page 67 Carnaby 125 - 200 Electrical system 20. Lampeggiatore posteriore sinistro 21. Fanale posteriore A. Lampade luce di posizione B. Lampade luce di stop 22. Lampeggiatore posteriore destro 23. Lampeggiatore anteriore sinistro 24. Proiettore A. Lampade luce di posizione B. Lampada luce abbagliante C.
  • Page 68 Carnaby 125 - 200 Electrical system Components arrangement ELE SYS - 68...
  • Page 69 Carnaby 125 - 200 Electrical system 1. Battery 2. Fuses 3. Spark plug 4. Coil 5. Pick-up 6. Voltage regulator 7. Control unit 8. Electric fan 9. Thermoswitch 10. Thermistor 11. Starter ELE SYS - 69...
  • Page 70 Carnaby 125 - 200 Electrical system 1.Battery - 2. Fuse terminal block: To get access to these components, unscrew the flap on the foot- rest and reach the battery compartment. 3. Spark plug - 4. Coil: Remove the inspection cover to reach the spark plug and the coil.
  • Page 71 Carnaby 125 - 200 Electrical system 7. Control unit: To get access to the control unit, remove the shield back plate. 8. Electric fan - 9. Thermoswitch: To get access to the electric fan, remove the front shield. 10. Thermistor: To get access to the thermistor, remove the helmet compartment.
  • Page 72 Carnaby 125 - 200 Electrical system 12. Clacson - 13. Dispositivo di comando pom- pa elettrica carburante: Per accedervi rimuovere il controscudo. I componenti sono situati nella parte bassa del veicolo. 14. Teleruttori - 15. Pompa carburante: Per ac- cedere a questi componenti rimuovere la fiancata laterale destra.
  • Page 73 Carnaby 125 - 200 Electrical system 1. Electronic ignition device 2. Engine stop switch 5. Fuse unit 7. Key switch 11. Battery 36. Spark plug 37. HV coil VERSIONE CON TELERUTTORE DI INIBIZIONE AVVIAMENTO LEGENDA 1. Dispositivo di accensione elettronica 2.
  • Page 74 Carnaby 125 - 200 Electrical system Headlights and automatic starter section 1. Electronic ignition device 2. Engine stop switch 5. Fuse unit 6. Automatic starter 7. Key switch 11. Battery 16. Light switch 17. Headlight remote control 18. Licence plate lamp 20.
  • Page 75 Carnaby 125 - 200 Electrical system F. High-beam warning light VERSIONE CON TELERUTTORE DI INIBIZIONE AVVIAMENTO LEGENDA 1. Dispositivo di accensione elettronica 5. Gruppo fusibili 6. Starter automatico 7. Commutatore a chiave 12. Batteria 17. Deviatore luci 18. Teleruttore proiettore 19.
  • Page 76 Carnaby 125 - 200 Electrical system F. Spia luce abbagliante Battery recharge and starting 1. Electronic ignition device 2. Engine stop switch 3. Magneto flywheel - Pick-up 4. Voltage regulator 5. Fuse unit 7. Key switch 8. Stop light remote control 9.
  • Page 77 Carnaby 125 - 200 Electrical system LEGENDA 2. Deviatore arresto motore 3. Volano magnete - Pick-up 4. Regolatore di tensione 5. Gruppo fusibili 7. Commutatore a chiave 8. Teleruttore luci stop 9. Pulsante di stop sul freno anteriore 10. Pulsante di stop sul freno posteriore 11.
  • Page 78 Carnaby 125 - 200 Electrical system Level indicators and enable signals section 5. Fuse unit 7. Key switch 11. Battery 25. Engine oil pressure sensor 26. Thermistor 27. Instrument panel G. Fuel level indicator H. Low fuel warning light L. Oil warning light M.
  • Page 79 Carnaby 125 - 200 Electrical system LEGENDA 5. Gruppo fusibili 7. Commutatore a chiave 12. Batteria 26. Sensore pressione olio motore 27. Termistore 28. Gruppo strumenti G. Indicatore livello carburante H. Spia riserva L. Spia olio M. Indicatore temperatura acqua 29.
  • Page 80 Carnaby 125 - 200 Electrical system Devices and accessories 1. Electronic ignition device 2. Engine stop switch 5. Fuse unit 7. Key switch 11. Battery 15. Wiring for antitheft device 19. Rear left turn indicator light 21. Rear right turn indicator light 22.
  • Page 81 Carnaby 125 - 200 Electrical system 32. Electric fan 33. Turn signal switch 34. Electric fuel pump 35. Electric pump control device VERSIONE CON TELERUTTORE DI INIBIZIONE AVVIAMENTO LEGENDA 1. Dispositivo di accensione elettronica 5. Gruppo fusibili 7. Commutatore a chiave 12.
  • Page 82 Carnaby 125 - 200 Electrical system 31. Pulsante clacson 32. Termointerruttore 33. Elettroventola 34. Commutatore lampeggiatori 35. Pompa elettrica carburante 36. Dispositivo comando pompa elettrica Checks and inspections Ignition circuit No spark plug Once the lack of power to the spark plug has been...
  • Page 83 Carnaby 125 - 200 Electrical system - HV primary coil check Disconnect the control unit connector and check that the cable between terminal No. 3 and terminal No. 8 is not interrupted (see figure). If non-conforming values are measured, check again the HV primary coil directly on the positive and negative terminals.
  • Page 84 Carnaby 125 - 200 Electrical system Pick-Up. - Disconnect the control unit connector and con- nect the positive terminal to connector No. 6 and the negative terminal to connector No. 8 (see fig- ure). - The multimeter end of a scale should be 200V.
  • Page 85 Carnaby 125 - 200 Electrical system Stator check Disconnect the connector from the voltage regu- lator and check there is continuity between any yellow cable and the other two cables. Electric characteristic Ohm value: 0.7 ÷ 0.9 Ohm Also check that all yellow cables are insulated from the ground connection.
  • Page 86 Carnaby 125 - 200 Electrical system Recharge system voltage check The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive terminal passing through the 15A protection fuse (No.
  • Page 87 Carnaby 125 - 200 Electrical system If no voltage is detected, connect the multimeter negative lead to the ground connection and the positive lead to the automatic starter White-Black cable; with the key switch set to «ON» check whether there is battery voltage; if there is no volt- age, check the cable harness connections to the key switch and make sure the 15A fuse (No.
  • Page 88 Carnaby 125 - 200 Electrical system If no voltage is detected, check the cable harness, the connections and make sure the 15A main fuse (No. 1) is in working order; otherwise, proceed as follows: - Jump terminals No. 1 (Blue-Black) and No. 5 (Green-Red) (see figure) and activate the turn in- dicator switch alternately to the right and left.
  • Page 89 Carnaby 125 - 200 Electrical system Fuses The electrical system has six protection fuses. To reach the board of fuses, unscrew the two screws «A» and remove the battery cover «B». CAUTION BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW.
  • Page 90 Carnaby 125 - 200 Electrical system Specification Desc./Quantity Protected circuits:Start-up circuit, Stop light remote control. Fuse No. 4 Capacity:7.5 A Protected circuits:Instrument panel gauges and warning lights, Horn, Light switch, Headlight remote control, Wiring for anti-theft device. Fuse No. 5 Capacity:3A Protected circuits:Electric pump control device.
  • Page 91 Carnaby 125 - 200 Electrical system BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL...
  • Page 92 Carnaby 125 - 200 Electrical system Smontaggio - Remove the helmet compartment. - Remove the side spoiler. - Empty the cooling circuit. - Remove the cover, disconnect the electrical ter- minal and unscrew the thermistor. Verifica LEGEND: 5. Fuse unit 7.
  • Page 93 Carnaby 125 - 200 Electrical system - Connect a tester «10» (set as ohmmeter) to the thermistor «2» as shown in the figure. - Immerse the thermistor in a container «11» with coolant. In the same container, immerse a thermometer «12»...
  • Page 94 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 95 Carnaby 125 - 200 Engine from vehicle Exhaust assy. Removal - Undo the two exhaust manifold fixings on the head. - Undo the three screws fixing the muffler to the support arm. - Remove the full muffler unit. To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
  • Page 96 Carnaby 125 - 200 Engine from vehicle - Empty the cooling system. - From the helmet compartment, disconnect the coolant return pipe «A» from the water tempera- ture thermostat. Disconnect the water temperature sensor «B». - Disconnect the cable «C» and the ground lead «D»...
  • Page 97 Carnaby 125 - 200 Engine from vehicle - From the scooter left side, disconnect the con- nector from the carburettor starter. - From the scooter right side, disconnect the spark plug. - From the scooter left side, undo and remove the engine ground screw «I»...
  • Page 98 Carnaby 125 - 200 Engine from vehicle - Undo and remove the nut fixing the engine on the swinging arm «M» - Slide off the engine pin on the swinging arm «N». Remove the engine together with the centre stand.
  • Page 99 INDEX OF TOPICS NGINE...

  • Page 100: Automatic Transmission

    Carnaby 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 101 Carnaby 125 - 200 Engine Version 125 - Remove the 4 screws and the housing. - To remove the intake throat on the transmission cover, just remove the 2 fixing screws indicated in the figure. Air duct filter To remove the intake throat on the transmission cover, remove the 2 fixing screws indicated in the figure.
  • Page 102 Carnaby 125 - 200 Engine Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by means of: Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm...
  • Page 103 Carnaby 125 - 200 Engine Refitting - Heat the roller and insert the bearing using the specific punch: Specific tools: Specific tooling 020455Y 10-mm guide - Refit the roller with the special screw. - Tighten to the specified torque. - Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing.

  • Page 104: Removing The Driven Pulley

    Carnaby 125 - 200 Engine Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inner diameter 15 and 17 mm).

  • Page 105: Removing The Clutch

    Carnaby 125 - 200 Engine Removing the clutch Clutch removal (125 cm³ H2O) Fit the driven pulley spring compressor specific tool with medium length pins screwed in position F from the tool internal side. - Insert the adapter ring 8 in the pins.
  • Page 106 Carnaby 125 - 200 Engine CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CON- TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE. Specific tooling 020444Y009 46x55 Wrench...
  • Page 107 Carnaby 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 108 Carnaby 125 - 200 Engine N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. - Measure the outer diameter of the pulley bushing. - Check the contact surface with the belt to make sure there are no flaws.
  • Page 109 Carnaby 125 - 200 Engine Inspecting the driven sliding half-pulley 125 - 200 version - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. Characteristic Movable driven half-pulley max. diameter Max. diameter admitted: Ø 41.08 mm Movable driven half-pulley standard diameter Standard diameter: Ø...

  • Page 110: Refitting The Driven Pulley

    Carnaby 125 - 200 Engine Refitting the driven pulley Driven pulley fitting - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure. - Fit the half-pulley over the bushing using the ap-...
  • Page 111 Carnaby 125 - 200 Engine - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. Inspecting the clutch spring - Misurare la lunghezza libera della molla della semipuleggia condotta mobile.
  • Page 112 Carnaby 125 - 200 Engine - Insert the spring with its plastic holder in contact with the clutch. - Insert the driving belt into the pulley unit accord- ing to their direction of rotation. - Insert the pulley unit with the belt into the tool.
  • Page 113 Carnaby 125 - 200 Engine Version 125 - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position «F» on the inside.
  • Page 114 Carnaby 125 - 200 Engine N.B. DURING THE SPRING PRELOADING PHASE, BE CARE- FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. N.B. AN EXCESSIVE QUANTITY CAN DAMAGE THE CLUTCH OPERATION. Specific tooling 020444Y011 adapter ring 020444Y009 46x55 Wrench...
  • Page 115 Carnaby 125 - 200 Engine - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool. N.B. DURING THE SPRING PRELOADING PHASE, BE CARE- FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING.

  • Page 116: Removing The Driving Pulley

    Carnaby 125 - 200 Engine Removing the driving pulley - Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Make sure the roller contact plate is not flawed or damaged on the grooved edge.
  • Page 117 Carnaby 125 - 200 Engine - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure the pulley sliding bushing outside di- ameter shown in the figure. - Check that the rollers are not damaged or worn.
  • Page 118 Carnaby 125 - 200 Engine Driving pulley removal - With the appropriate tool placed into the internal slots, remove the nut with the built-in Belleville washer. Appropriate tools: Specific tooling 020442Y Pulley lock wrench - Remove the entire start-up crown unit with the torque limiter.
  • Page 119 Carnaby 125 - 200 Engine Refitting the driving pulley - 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 120 Carnaby 125 - 200 Engine - Preassemble the movable half-pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation. - Check that the roller contact plate does not have flaws and is not damaged on the grooved edge.
  • Page 121 Carnaby 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 122 Carnaby 125 - 200 Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil guard as in the figure.
  • Page 123 Carnaby 125 - 200 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents.
  • Page 124 Carnaby 125 - 200 Engine Refitting the hub cover bearings - To fit the hub housing bearings, the engine crank- case and the cover must be heated with the spe- cial heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
  • Page 125 Carnaby 125 - 200 Engine 020363Y 20 mm guide Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dowels.
  • Page 126 Carnaby 125 - 200 Engine Flywheel cover - Remove the two clamps, the two couplings and empty the cooling system. - Remove the 4 retainers and the flywheel cover. Removing the hub cover - Remove the two clamps, the two couplings and empty the cooling system.

  • Page 127: Removing The Stator

    Carnaby 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 128 Carnaby 125 - 200 Engine - Place the flywheel with the top dead centre mark aligned with the crankcase. - Place the flywheel cover by aligning the reference marks of the drive and the crankcase cover. - Reassemble the cover on the engine, placing the three connectors in the drive for the water pump.
  • Page 129 Carnaby 125 - 200 Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly.
  • Page 130 Carnaby 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. TAMPERPROOF SCREWS ARE SUPPLIED WITH 125 CC MODELS.
  • Page 131 Carnaby 125 - 200 Engine ENG - 131...
  • Page 132 Carnaby 125 - 200 Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes.

  • Page 133: Removing The Cylinder Head

    Carnaby 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 134 Carnaby 125 - 200 Engine - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool. - Remove the lower spring supports. CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOG- NISE THEIR ORIGINAL POSITION ON THE HEAD.
  • Page 135 Carnaby 125 - 200 Engine ENG - 135...

  • Page 136: Inspecting The Small End

    Carnaby 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 137 Carnaby 125 - 200 Engine Inspecting the wrist pin - Verificare il diametro esterno dello spinotto. - Calcolare il gioco di accoppiamento piede di biel- la spinotto. - Misurare il diametro delle portate sul pistone. - Calcolare il gioco di accoppiamento spinotto pi- stone.
  • Page 138 Carnaby 125 - 200 Engine THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON. Caratteristiche tecniche Diametro spinotto: Diametro standard : 200 68,990 ÷ 69,018 Pin diameter Standard diameter: 125 cc 56.997 ÷...

  • Page 139: Inspecting The Piston

    Carnaby 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 140: Removing The Piston

    Carnaby 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 141 Carnaby 125 - 200 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, without 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. Keeping the zero position, as- semble the tool on the cylinder and lock it with 2 supplied nuts as shown in the figure.
  • Page 142 Carnaby 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 143: Inspecting The Cylinder Head

    Carnaby 125 - 200 Engine Inspecting the cylinder head Head check - 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 144 Carnaby 125 - 200 Engine bearing «A» Ø 12.000 - 12.018 mm bearing «B» Ø 20.000 ÷ 20.021 mm bearing «C» Ø 37.000 - 37.025 mm Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out.
  • Page 145 Carnaby 125 - 200 Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
  • Page 146 Carnaby 125 - 200 Engine Inspecting the valves - Measure the width of the sealing surface on the valve seats and on the valves. Sealing surface width: After use: Intake and ex- haust: 1.6 mm - If any of the sealing surfaces on the valves is...
  • Page 147 Carnaby 125 - 200 Engine Valve check standard length Outlet: 94.4 mm Valve check standard length Inlet: 94.6 mm Valve check Maximum admissible clearance Outlet: 0.072 mm Valve check Maximum admissible clearance Inlet: 0.062 mm Valve check standard clearance Outlet: 0.025 ÷ 0.052 mm Valve check standard clearance Inlet: 0.013 ÷...
  • Page 148 Carnaby 125 - 200 Engine - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the sur- face of contact with the articulated register termi- nal.
  • Page 149 Carnaby 125 - 200 Engine Outlet: 0.072 mm Valve check Maximum admissible clearance Inlet: 0.062 mm Valve check standard clearance Outlet: 0.025 ÷ 0.052 mm Valve check standard clearance Inlet: 0.013 ÷ 0.040 mm Valve check Minimum admissible diameter Outlet: 4.95 mm Valve check Minimum admissible diameter Inlet: 4.96 mm...
  • Page 150 Carnaby 125 - 200 Engine 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams.
  • Page 151 Carnaby 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 152 Carnaby 125 - 200 Engine - Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley.
  • Page 153 Carnaby 125 - 200 Engine - 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. - Lubricate the stud bolt threading. - Tighten up the nuts to a pre-torque of 7±1 N·m - Rotate by a 180°...
  • Page 154 Carnaby 125 - 200 Engine Refitting the intake manifold Fit the intake manifold and do up the three screws. N.B. USE COMMERCIALLY AVAILABLE INSERTS AND INSERT HOLDERS FOR THE SPECIAL SCREWS FOR 125 CM³ MODELS. Crankcase - crankshaft Splitting the crankcase halves engine crankcase opening ble>...
  • Page 155 Carnaby 125 - 200 Engine - Remove the flywheel cover together with the water pump, the flywheel and the stator as described in the magneto fly- wheel chapter. - Remove the oil filter and the oil pressure switch. - Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter.
  • Page 156 Carnaby 125 - 200 Engine - Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crankshaft be- tween these surfaces, as shown in the diagram.
  • Page 157 Carnaby 125 - 200 Engine MODIFIED BY THE RADIUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS. N.B. The crankshaft of the 200 cm³ version has two steel shim washers. Take note of their fitting position. Specific tooling 020262Y Crankcase splitting strip Characteristic Crankshaft bearings: Standard diameter: Cat.
  • Page 158 Carnaby 125 - 200 Engine The connecting rod head bushings cannot be re- placed. For the same reason, the connecting rod may not be replaced and, when cleaning the crankshaft, be very careful that no impurities get in through the shaft's lubrication holes.
  • Page 159 Carnaby 125 - 200 Engine Off-line maximum allowed: A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm Specific tooling 020335Y Magnetic support for dial gauge 020074Y Support base for checking crankshaft alignment Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts.
  • Page 160 Carnaby 125 - 200 Engine 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 shown in the diagram, could cause a drop in the oil pressure lubricating the main bearings and con- nection rod.
  • Page 161 Carnaby 125 - 200 Engine For the 200 models reposition the shim washers as in the original fitting. - Fit the 11 screws and tighten them to the pre- scribed torque. - Lubricate the flywheel oil seal. - Using the appropriate tool, assemble the oil seal.
  • Page 162 Carnaby 125 - 200 Engine ENG - 162...

  • Page 163: Oil Pressure Check

    Carnaby 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 164 Carnaby 125 - 200 Engine - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electrical connexion 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 165: Oil Pump

    Carnaby 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 166 Carnaby 125 - 200 Engine - Use a new oil seal upon refitting. - Prepare the new oil seal, lubricating the sealing lip. - Preassemble the oil seal with the specific tool, positioning the screws. - Place the sheath over the crankshaft.
  • Page 167 Carnaby 125 - 200 Engine - Remove the cover of the pump control pulley us- ing the two retainers, as shown in the figure. - Block the rotation of the oil pump control pulley inserting a screwdriver through one of its two holes.
  • Page 168 Carnaby 125 - 200 Engine Inspection - Remove the two screws and the oil pump cover. - Remove the clip retaining the innermost rotor. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible Replace the snap ring.
  • Page 169 Carnaby 125 - 200 Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and the sprocket wheel, as described in the "Trans- mission" chapter. - Drain the oil as described previously.
  • Page 170 Carnaby 125 - 200 Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.
  • Page 171 Carnaby 125 - 200 Engine - Switch the pump to pressure mode (PRES- SURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is consid- ered to be normal. If anomalies are detected, replace the pump.

  • Page 172: Fuel Supply

    Carnaby 125 - 200 Engine the valve opens and the depression is suddenly set to zero. Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it.

  • Page 173: Removing The Carburettor

    Carnaby 125 - 200 Engine Removing the carburettor carburettor removal ble> - To detach the carburettor from the engine, move the air filter and remove the throttle control transmission, the au- tomatic starter connection, the clamps anchoring the car- burettor to the filter housing...
  • Page 174 Carnaby 125 - 200 Engine - Remove the accelerating pump piston with the ring nut, the hood, the O-Ring and the spring from the chamber as shown in the figure. - Adequately support the car- burettor and using a pin and hammer;...
  • Page 175 Carnaby 125 - 200 Engine CAUTION - Do not attempt to remove parts embedded in the carburettor body, such as: fuel supply pipe, plunger housing, starter nozzle, pit cover for progressions and inlet nozzle, minimum and max- imum air gauge, throttle valve control shaft. Do not remove throttle-shaft connecting screws.
  • Page 176 Carnaby 125 - 200 Engine 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 to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, and the intake fitting.
  • Page 177 Carnaby 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 178 Carnaby 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 179 Carnaby 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 180 Carnaby 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 181 Carnaby 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 182 Carnaby 125 - 200 Engine ENG - 182...
  • Page 183 Carnaby 125 - 200 Engine ENG - 183...
  • Page 184 Carnaby 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 185 Carnaby 125 - 200 Engine - Reassemble the vacuum valve on the carburettor body taking care that the tapered pin is inserted into the sprayer. - 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 186 Carnaby 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 187 Carnaby 125 - 200 Engine plate with the machined side contacting the starter, tighten the 2 fixing screws. - Position the starter as shown in the figure. - Assemble the protection casing. Characteristic Check the auto starter: Protrusion Value for Walbro 12.5 ÷...
  • Page 188 Carnaby 125 - 200 Engine - The correct warm up time depends on the ambi- ent temperature. - If protrusion, resistance or timing values are dif- ferent from the ones prescribed, replace the start- - Assemble the starter to the carburettor being...
  • Page 189 Carnaby 125 - 200 Engine - Connect the vehicle to the exhaust fumes analy- ser inserting the probe into a sealed extension pipe placed at the muffler exit end. - Connect a millimetre thermometer (020331y) on the sump, using a cover with oil expressly pre- pared for probes.
  • Page 190 Carnaby 125 - 200 Engine is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. - If it were difficult to ???? adjustment CO check accurately: - That the carburettor is clean - That the automatic starter is efficient...
  • Page 191 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 192: Removing The Front Wheel

    Carnaby 125 - 200 Suspensions Front Removing the front wheel - Remove the front calliper. - Loosen the wheel axle lock-nut. - Loosen the two wheel axle safety screws on the fork leg, on the brake calliper side. - Pull out the wheel axle.
  • Page 193 Carnaby 125 - 200 Suspensions * Either tool can be used. - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle,...
  • Page 194 Carnaby 125 - 200 Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube...
  • Page 195 Carnaby 125 - 200 Suspensions - Refit the cap and tighten the five fixing screws. Refitting the front wheel - Grease the wheel axle, then install it from the tone wheel side and install the tone wheel proper- - Tighten the wheel axle nut to the prescribed tor- que.

  • Page 196: Front Fork

    Carnaby 125 - 200 Suspensions Removal - Remove the front handlebar cover. - Remove the rear handlebar cover. - Remove the fixing pin. - Remove the handlebar resting it on the shield back plate. If you want to remove the fork, proceed as follows: - Remove the front handlebar cover.
  • Page 197 Carnaby 125 - 200 Suspensions Removal - Remove the front wheel. - Remove the handlebar. - Using the appropriate tool, loosen and remove the upper ring nut, the distancing washer, the counter ring nut and the spacer ring. - Extract the fork.
  • Page 198 Carnaby 125 - 200 Suspensions - Remove the first spring featuring 15 turns. - Remove the spring support plate. - Remove the second spring featuring 21 turns. - Drain the oil. - Separate the stem from the leg by removing the screws with copper washer shown in the figure.
  • Page 199 Carnaby 125 - 200 Suspensions Check there are no signs of wear or seizing up between the stem and the leg. Otherwise, replace the damaged parts. Characteristic Maximum leg diameter 35.10 mm Minimum stem diameter 34.90 mm Check that the oil holes on the pumping element are not clogged.
  • Page 200 Carnaby 125 - 200 Suspensions - Insert the contrast spring into the pumping mem- ber. - Insert the pumping element inside the stem. - Insert the pumping element guide bushing at the lower stem end. - Insert the stem in the leg being careful not to let the stem guide bushing come out.
  • Page 201 Carnaby 125 - 200 Suspensions - Loosen the fork clamp screws and ensure the stem closure cap is fitted properly on the clamp. - Tighten the clamp screws to the prescribed tor- que. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor...
  • Page 202 Carnaby 125 - 200 Suspensions - Using a 19 mm hexagonal spanner, extract the roller bearing. Specific tooling 020458Y Puller for lower bearing on steering tube - Insert the a new plate and a new dust guard in the steering tube - Insert a new roller bearing in the roller tube.
  • Page 203 Carnaby 125 - 200 Suspensions - Remove the first spring featuring 15 turns. - Remove the spring support plate. - Remove the second spring featuring 21 turns. - Drain the oil. - Separate the stem from the leg by removing the screws with copper washer shown in the figure.
  • Page 204 Carnaby 125 - 200 Suspensions Specification Desc./Quantity Allowable limit after use: 21-turn spring: 173.7 mm Check there are no signs of wear or seizing up between the stem and the leg. Otherwise, replace the damaged parts. Characteristic Maximum leg diameter 35.10 mm...
  • Page 205 Carnaby 125 - 200 Suspensions - Insert the contrast spring into the pumping mem- ber. - Insert the pumping element inside the stem. - Insert the pumping element guide bushing at the lower stem end. - Insert the stem in the leg being careful not to let the stem guide bushing come out.
  • Page 206 Carnaby 125 - 200 Suspensions - Loosen the fork clamp screws and ensure the stem closure cap is fitted properly on the clamp. - Tighten the clamp screws to the prescribed tor- que. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor...
  • Page 207 Carnaby 125 - 200 Suspensions Removal - Remove the fork - Check that the upper ball bearing and the seat of the lower roller bearings do not show signs of wear or pricking. In case of replacement, proceed as follows:...

  • Page 208: Removing The Rear Wheel

    Carnaby 125 - 200 Suspensions Removing the rear wheel - Remove the exhaust silencer. - Unscrew the shock absorber lower clamp and rotate the shock absorber towards the scooter rear part. - Remove the cotter pin and the cap. - Loosen the nut and collect the spacer.
  • Page 209 Carnaby 125 - 200 Suspensions - Remove the five screws fixing the wheel to the hub. - Remove the wheel and collect the conical spacer. Refitting the rear wheel - Carry out the removal operations but in reverse order, observing the prescribed tightening torques.
  • Page 210 Carnaby 125 - 200 Suspensions - Remove the pin from the silent bloc. - Once the swinging arm on the engine side is re- leased, release the swinging arm on the frame side, operating on both sides. - Loosen the nut and collect the washer.
  • Page 211 Carnaby 125 - 200 Suspensions - Remove the side spoilers. - Remove the footrest. - Check the axial clearance between the two swinging arms using a thickness gauge. - If non-conforming values are detected, remove the swinging arm and replace the Teflon spacer bushings.

  • Page 212: Shock Absorbers

    Carnaby 125 - 200 Suspensions Refitting - Carry out removal operations in reverse order. - Tighten to the prescribed torques. SWINGING ARM FITTING Name Torque in Nm Swinging arm on engine side - Engine Silent bloc - Frame Swinging arm on frame side - Frame...
  • Page 213 Carnaby 125 - 200 Suspensions - Loosen the nut fixed to the muffler support on the other side. - Undo the two upper nuts (one on each side) fixing the shock absorber spring unit to the frame and remove the shock absorbers themselves.
  • Page 214 Carnaby 125 - 200 Suspensions - Remove the split pin and safety cover; - Unscrew the wheel axle nut; to prevent the wheel from rotating, use the rear brake and collect the spacer. - Remove the support arm. See also Exhaust assy.
  • Page 215 Carnaby 125 - 200 Suspensions - Heat the bearing seat using the heat gun - Using the special punch, install a new bearing in the seat as shown in the photograph Specific tooling 020376Y Adaptor handle 020151Y Air heater Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
  • Page 216 Carnaby 125 - 200 Suspensions Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °C and +120 °C; NLGI 2; ISO-L-XBCIB2 Locking torques (N*m) Bolt fixing the centre stand to the frame 25 ÷ 30...
  • Page 217 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 218: Rear Brake Calliper

    Carnaby 125 - 200 Braking system Interventions rules WARNING BRAKING SYSTEM FLUID IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THE CONTACT AREA WELL WITH ABUNDANT WATER. THE BRAKE FLUID DRAINED FROM THE SYSTEM IS HARMFUL TO THE ENVIRONMENT. COL- LECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONS IN FORCE.
  • Page 219 Carnaby 125 - 200 Braking system - Undo the screws fixing the calliper support to the engine. Refitting - Fix the brake calliper support plate to the crank- case and the brake calliper to the bracket, tight- ening the screws to the prescribed torque.
  • Page 220 Carnaby 125 - 200 Braking system Removal - Make sure the brake pipes and the joint are in good conditions. Remove and repair the calliper in the event of fluid leaks. - Disconnect the brake fluid pipe from the calliper, pouring the fluid inside a container.
  • Page 221 Carnaby 125 - 200 Braking system - that the guides of the fixed plate are not scratched or eroded, otherwise replace the entire plate; - that the brake pad check spring works properly. Refitting 1) insert the pistons (6) and the sealing rings (7) in the body;...
  • Page 222 Carnaby 125 - 200 Braking system ALL THE SEALS AND GASKETS MUST BE REPLACED EV- ERY TIME THE CALLIPER IS SERVICED. Locking torques (N*m) Brake fluid pipe-calliper fitting Pad fas- 20 ÷ 25 tening pin 19.6 ÷ 24.5 Refitting - When refitting, tighten the nuts to the prescribed torque.

  • Page 223: Front Brake Disc

    Carnaby 125 - 200 Braking system Removing the rear wheel Refitting - For the installation, position the disc correctly using the arrow stamped on it as reference. - Tighten the screws to the prescribed torque and apply the recommended product.
  • Page 224 Carnaby 125 - 200 Braking system Removal Proceed as follows: - Remove the front wheel. - Loosen the five disc fixing screws. - Thoroughly clean the seats on the front wheel hub and on the disc. See also Removing the front wheel Refitting For fitting, position the disc correctly using the arrow stamped on it as reference.

  • Page 225: Front Brake Pads

    Carnaby 125 - 200 Braking system - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits. - If this is not the case, replace the disc and repeat the test.
  • Page 226 Carnaby 125 - 200 Braking system Locking torques (N*m) Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5 Rear brake pads Removal Proceed as follows: - Remove the rear brake calliper - Remove the two pins holding the brake pads.
  • Page 227 Carnaby 125 - 200 Braking system Rear - combined Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir.
  • Page 228 Carnaby 125 - 200 Braking system Front Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir. - Through the bleed screw on the brake calliper, bleed the system using a hose of adequate diam- eter.
  • Page 229 Carnaby 125 - 200 Braking system Front brake pump Removal - Remove the front handlebar cover. - Remove the rear handlebar cover. - Drain the braking system. - Disconnect the brake fluid pipe from the pump, paying attention to a possible escape of remaining brake fluid.
  • Page 230 Carnaby 125 - 200 Braking system 5. Seal ring 6. Piston 7. Gasket 8. Spring 9. Tank CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED. Refitting - Upon refitting, perform the operation but in reverse order.
  • Page 231 Carnaby 125 - 200 Braking system - Loosen the two fixing screws of the stand and remove together with the rear view mirror. - Remove the front brake pump together with the lever. See also Rear - combined Rear handlebar cover Refitting - Upon refitting, perform the operation but in reverse order.
  • Page 232 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 233: Circuit Diagram

    Carnaby 125 - 200 Cooling system Circuit diagram COOLING CIRCUIT Specification Desc./Quantity Fluid cooling circuit Thermostat with By-Pass COOL SYS - 233...
  • Page 234 Carnaby 125 - 200 Cooling system Specification Desc./Quantity Expansion tank Radiator Carburettor heating circuit Electric fan check KEY: 5. Fuse unit 11. Battery 31. Thermoswitch 32. Electric fan Electric fan operation check To carry out the electric fan operation check, pro- ceed as follows: - Remove the front shield.
  • Page 235 Carnaby 125 - 200 Cooling system If it does not work: - Make sure the connector is properly inserted. - Rotate the fan manually and check that the blades do not touch the support. If the fan rotates freely: - Check the battery recharge system and the main fuse.

  • Page 236: Coolant Replacement

    Carnaby 125 - 200 Cooling system Coolant replacement Emptying - Remove the right side fairing. - Remove the right lower spoiler. - Unscrew and remove the expansion tank cap. - Slide off the sleeve after loosening the clamp. - Let the coolant drain into a container of adequate capacity.
  • Page 237 Carnaby 125 - 200 Cooling system - Slide the thermostat off the cover. Check - Visually check that the thermostat is not dam- aged. - Prepare a metal container with approx. 1 litre of water. - Immerse the thermostat, keeping it in the centre of the container.
  • Page 238 Carnaby 125 - 200 Cooling system COOL SYS - 238...
  • Page 239 INDEX OF TOPICS CHAS HASSIS...
  • Page 240 Carnaby 125 - 200 Chassis Seat - Remove the cover by undoing the two screws. - Operating on both sides, undo the four screws and remove the spark plug inspection cover pulling it upwards. - With the saddle opened, remove the cotter pin.

  • Page 241: Rear Rack

    Carnaby 125 - 200 Chassis Rear rack - Undo the five fixing screws. Rear handlebar cover - Remove the front handlebar cover. - Remove the rear-view mirrors. - Remove the four frame fixing screws from both sides, as shown in the figure.
  • Page 242 Carnaby 125 - 200 Chassis Front handlebar cover - Operating on both sides of the scooter, remove the two inspection covers of the brake calliper res- ervoir «A». - Undo the two screws «B». - Remove the five screws «C».
  • Page 243 Carnaby 125 - 200 Chassis Headlight assy. - Undo the four screws «A» and remove the front case «B». - Undo the screw «C» and remove the cover to reach the expansion tank cap. - Operating on both sides of the scooter, undo the eight screws «D».
  • Page 244 Carnaby 125 - 200 Chassis - Operating on both sides of the scooter, undo the six screws «E». - Undo the two screws «F» connecting the head- light assembly to the turn indicators. - Undo the six screws «G» connecting the headlight assembly to the legshield and remove the headlight assembly.
  • Page 245 Carnaby 125 - 200 Chassis - Undo the screws fixing the legshield to the frame above the bag hook. - Undo the screw «C» and remove the cover to reach the expansion tank cap. - Unscrew the expansion tank cap.
  • Page 246 Carnaby 125 - 200 Chassis Knee-guard - Remove the front handlebar cover. - Remove the rear handlebar cover. - Undo the screws of the cover of the expansion tank compartment and remove the cap. - Undo the screw of the bag hook.
  • Page 247 Carnaby 125 - 200 Chassis Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the cylinder retaining spring. The spring must then be removed as shown in the figure, allowing the lock spring to be pressed out.
  • Page 248 Carnaby 125 - 200 Chassis - Lift the saddle and remove the three screws «A» fixing the tail light fairing B». - Operating on both sides, undo the screw inside the rear wheel housing «C» and disconnect the connector. - Undo the two screws «D».
  • Page 249 Carnaby 125 - 200 Chassis - Undo the four centre screws. - Operating on both sides, undo the two screws on the lower part. - Remove the footrest. Side fairings - Remove the cover by undoing the two screws. - Operating on both sides, undo the four screws and remove the spark plug inspection cover pulling it upwards.
  • Page 250 Carnaby 125 - 200 Chassis - Remove the luggage rack. - Remove the upper fairing of the rear light unit by undoing the three screws indicated. - Undo the two screws indicated. - Unfold the passenger footrest and undo the two screws.

  • Page 251: Rear Mudguard

    Carnaby 125 - 200 Chassis Rear mudguard - Undo the two screws « A» under the air filter. - Undo the two screws «B» and the screw «C» supporting the fuel supply bracket. - Unscrew the shock absorber lower clamp and rotate the shock absorber towards the scooter rear part.
  • Page 252 Carnaby 125 - 200 Chassis - Undo the screws fixing the helmet compartment to the frame. - Undo the screws fixing the saddle lock. - Undo the fuel tank cap, remove the rubber fuel recovery tank and disconnect the bleed pipe.

  • Page 253: Fuel Tank

    Carnaby 125 - 200 Chassis - Remove the external screw and the spoiler. Fuel tank - Remove the helmet compartment. N.B. THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY. - Undo the two screws, on the rear wheel housing, connecting the tank to the frame and collect the washer.

  • Page 254: Front Mudguard

    Carnaby 125 - 200 Chassis - Disconnect the fuel hose. N.B. THIS OPERATION SHOULD PREFERABLY BE PER- FORMED WITH THE TANK EMPTY. Front mudguard - Undo the three screws fixing the front mudguard to the fork plate inside the mudguard.
  • Page 255 Carnaby 125 - 200 Chassis - Undo the screw fixing the radiator to the frame. - Detach the radiator and the electric fan. - Once refitted, bleed the cooling system. Expansion tank - Remove the shield back plate. - Remove the radiator cover and disconnect the headlight assembly connectors.
  • Page 256 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 257 Carnaby 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 258 Carnaby 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 259 Carnaby 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 260 INDEX OF TOPICS TIME...
  • Page 261 Carnaby 125 - 200 Time Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit. 003064 Engine oil - Change 003057 Engine retainer - Tighten nuts TIME - 261...
  • Page 262 Carnaby 125 - 200 Time Crankcase CRANKCASE Code Action Duration 001153 Crankcase halves gasket - Replace- ment 001133 Engine crankcase - Replacement TIME - 262...
  • Page 263 Carnaby 125 - 200 Time Crankshaft CRANKSHAFT Code Action Duration 001099 Oil seal, flywheel side - Replacement 001117 Crankshaft - Replacement TIME - 263...
  • Page 264 Carnaby 125 - 200 Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001154 Pin ring piston unit - Service TIME - 264...
  • Page 265 Carnaby 125 - 200 Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 001083 Thermistor - Replacement 001057 Thermostat - Replacement TIME - 265...
  • Page 266 Carnaby 125 - 200 Time Rocker arms support assy. CAMSHAFT - ROCKING LEVERS Code Action Duration 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 266...

  • Page 267: Cylinder Head Cover

    Carnaby 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 - 267...
  • Page 268 Carnaby 125 - 200 Time Chain tensioner CHAIN TIGHTENER Code Action Duration 001129 Chain tensioner - Service and Re- placement 001124 By pass lubrication - Replacement TIME - 268...

  • Page 269: Oil Filter

    Carnaby 125 - 200 Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Replacement TIME - 269...

  • Page 270: Driven Pulley

    Carnaby 125 - 200 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 003072 Clutch unit - Wear check 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 270...
  • Page 271 Carnaby 125 - 200 Time Oil pump PUMP - OIL SUMP UNIT Code Action Duration 001125 Chain guide pads - Replacement 001051 Belt/ Timing chain - Replacement 001042 Oil pump - Service 001112 Oil pump - Replacement 001122 Oil pump chain - Replacement...
  • Page 272 Carnaby 125 - 200 Time Final gear assy. FINAL DRIVE Code Action Duration 001010 Gear reduction unit - Inspection 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replacement TIME - 272...
  • Page 273 Carnaby 125 - 200 Time Driving pulley PULLEY REAR VIEW Code Action Duration 001086 rear-view half-pulley - Replacement 001011 Driving belt - Replacement 001066 Driving pulley - Removal and Refit- ting 001006 driving pulley - Service TIME - 273...

  • Page 274: Flywheel Magneto

    Carnaby 125 - 200 Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - re- place 001131 Transmission air intake - Replace- ment Flywheel magneto MAGNETO FLYWHEEL AND SECONDARY AIR...
  • Page 275 Carnaby 125 - 200 Time Code Action Duration 001161 Secondary air filters - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001174 SAS valve - Replacement 001163 SAS valve / Head connection - Re- placement Carburettor CARBURETTOR Code...
  • Page 276 Carnaby 125 - 200 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001092 Exhaust manifold - Replacement TIME - 276...

  • Page 277: Air Cleaner

    Carnaby 125 - 200 Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement/Cleaning 001015 Air filter box - Replacement 004122 Carburettor air cleaner attachment - Replacement TIME - 277...
  • Page 278 Carnaby 125 - 200 Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement TIME - 278...
  • Page 279 Carnaby 125 - 200 Time Centre-stand CENTRE AND SIDE STANDS Code Action Duration 004004 Stand - Replacement TIME - 279...
  • Page 280 Carnaby 125 - 200 Time Legshield spoiler LEGSHIELD - SPOILER Code Action Duration 004064 Legshield - Replacement 004053 Spoiler - Replacement TIME - 280...
  • Page 281 Carnaby 125 - 200 Time Side fairings SIDE COVERS Code Action Duration 004085 Fairing (1) - Replacement 004012 Rear side panels - Replacement 004052 Bumper - Replacement TIME - 281...
  • Page 282 Carnaby 125 - 200 Time Footrests MATS AND COVERS Code Action Duration 004075 Front mat - Replacement 004079 Passenger footrest (1) - Replace- ment 004015 Footrests - Remov. and Refit. TIME - 282...
  • Page 283 Carnaby 125 - 200 Time Rear cover REAR SHIELD Code Action Duration 004065 Legshield rear section - Remov. and Refit. TIME - 283...
  • Page 284 Carnaby 125 - 200 Time Central cover CENTRAL COVER Code Action Duration 004011 Frame central cover - Replacement 002082 Fuel tank cap opening drive - Re- placement TIME - 284...
  • Page 285 Carnaby 125 - 200 Time Underseat compartment HELMET COMPARTMENT- SEAT ELECTRIC OPENING-LICENCE PLATE HOLDER Code Action Duration 002083 Saddle opening transmission - Re- placement Saddle opening transmis- sion - Replacement 004016 Helmet compartment - Remov. and Refit. 004106 Underseat band - Replacement...
  • Page 286 Carnaby 125 - 200 Time Mudguard FRONT AND REAR MUDGUARDS Code Action Duration 004009 Rear mudguard - Replacement 004002 Front mudguard - Replacement TIME - 286...
  • Page 287 Carnaby 125 - 200 Time Fuel tank FUEL TANK Code Action Duration 005010 Tank float - Replacement 004109 Fuel tank breather - Replacement 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement TIME - 287...
  • Page 288 Carnaby 125 - 200 Time Expansion tank EXPANSION TANK Code Action Duration 007001 Expansion tank - Replacement 007013 Expansion tank - radiator connection pipe - Replacement 001052 Coolant and air bleeding - Replace- ment TIME - 288...
  • Page 289 Carnaby 125 - 200 Time Radiator RADIATOR Code Action Duration 007014 Radiator thermal switch - Replace- ment 007002 Radiator water - Replacement 007016 Complete fan with support - Replace- ment 007003 Coolant delivery and return pipe - Re- placement TIME - 289...
  • Page 290 Carnaby 125 - 200 Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Remov. and Refit. TIME - 290...
  • Page 291 Carnaby 125 - 200 Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Fork unit - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 004119 Bearing/upper steering fifth wheel - Replacement 003002 Steering fifth wheel - Replacement...

  • Page 292: Handlebar Covers

    Carnaby 125 - 200 Time Handlebar covers HANDLEBAR COVER Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment TIME - 292...
  • Page 293 Carnaby 125 - 200 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Throttle grip - Replacement 002037 Brake or clutch lever - Replacement 002071 Left knob - Replacement 002024 Front brake pump - Removal and Re- fitting 002067 Rear brake pump - Replacement...
  • Page 294 Carnaby 125 - 200 Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chassis con- nection - Replacement 004058 Silent block - Replacement TIME - 294...
  • Page 295 Carnaby 125 - 200 Time Brake hoses BRAKE PIPING Code Action Duration 002039 Front brake calliper - Replacement 002040 Front brake calliper - Service 002021 Front brake piping - Replacement 002047 Front brake fluid and system bleed- ing plug - Repl.
  • Page 296 Carnaby 125 - 200 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 296...

  • Page 297: Seat Lock

    Carnaby 125 - 200 Time Seat lock SADDLE LOCK MECHANISM Code Action Duration 004054 Saddle lock catch - Replacement TIME - 297...
  • Page 298 Carnaby 125 - 200 Time Instrument panel INSTRUMENT PANEL Code Action Duration 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement TIME - 298...
  • Page 299 Carnaby 125 - 200 Time Rear rack LUGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement TIME - 299...
  • Page 300 Carnaby 125 - 200 Time Locks LOCKS Code Action Duration 005016 Key switch - Replacement 004010 Anti-theft lock - Replacement TIME - 300...

  • Page 301: Turn Signal Lights

    Carnaby 125 - 200 Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - Replacement 005005 Taillight - Replacement 005008 Headlight bulbs - Replacement 005031 Licence plate light bulb - Replace- ment 005032 Licence plate light glass - Replace-...

  • Page 302: Front Wheel

    Carnaby 125 - 200 Time Front wheel FRONT WHEEL Code Action Duration 002041 Brake disc - Replacement 003037 Front wheel rim - Remov. and Refit. 003038 Front wheel axle - Remov. and Refit. 003040 Front wheel bearings - Replacement 003047...

  • Page 303: Rear Wheel

    Carnaby 125 - 200 Time AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement...
  • Page 304 Carnaby 125 - 200 Time Electric start ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement TIME - 304...

  • Page 305: Fuel Pump

    Carnaby 125 - 200 Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Carburettor pump hose - Replace- ment 004089 Tank-pump hose - Replacement 004072 Fuel filter - Replacement TIME - 305...
  • Page 306 Carnaby 125 - 200 Time Electric devices TIME - 306...
  • Page 307 Carnaby 125 - 200 Time ELECTRIC DEVICES Code Action Duration 001023 Control unit - Replacement 001069 HV coil - Replacement 001094 Spark plug hood - Replacement 005001 Electrical system - Replacement 005003 Horn - Replacement 005035 Headlight remote control - Replace-...
  • Page 308 Carnaby 125 - 200 Time Secondary air box ECONDARY AIR HOUSING Code Action Duration 001162 Secondary air housing - Replace- ment 001161 Secondary air filter - Replacement / Cleaning 001174 SAS valve - Replacement 001163 SAS valve / Head connection - Re-...
  • Page 309 Air filter: 47 Battery: 60, 76, 90 Brake: 218, 219, 222, 223, 225, 226, 229, 230, 295 Carburettor: 13, 42, 173, 181, 275 Coolant: 236 Engine oil: 48 Engine stop: Fuel: 59, 172, 253, 287, 305 Fuses: 89 Headlight: 54, 243 Hub oil: 46 Identification: 8 Instrument panel: 241, 298...
  • Page 310 Tyres: 11...

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Carnaby 200

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