PIAGGIO Liberty 200 4tempi Manuals

Manuals and User Guides for PIAGGIO Liberty 200 4tempi. We have 1 PIAGGIO Liberty 200 4tempi manual available for free PDF download: Workshop Manual

PIAGGIO Liberty 200 4tempi Workshop Manual (213 pages)

Brand: PIAGGIO | Category: Scooter | Size: 11.77 MB

Index of Topics
5
Characteristics
6
Safety Rules
7
Maintenance Rules
7
Vehicle Identification
8
Dimensions and Mass
8
Weight and Dimensions
8
Engine
9
Secondary Air
11
Carburettor
11
125Cc Version
11
200Cc Version
12
Tightening Torques
12
Carburettor Setting
12
Overhaul Data
13
Assembly Clearances
14
Cylinder - Piston Assy.
14
Piston Rings
14
Crankcase - Crankshaft - Connecting Rod
15
Sealing Rings (200)
15
Axial Clearance between Crankshaft and Connecting Rod (125)
15
Axial Clearance between Crankshaft and Crankshaft Half-Bearings
15
Table of Recommended Products
17
Tooling
18
Tools
19
Maintenance
28
Maintenance Chart
29
Every 2 Years
29
Every 3000 Km
29
After 1000 Km
29
After 24000 Km, 48000 Km
30
After 30000 Km, 42000 Km, 66000 Km
30
After 36000 Km
31
After 72,000 Km
31
CO Check
32
Specific Tooling
33
Troubleshooting
34
Engine Poor Performance
35
Rear Wheel Spins at Idle
35
Starting Difficulties
35
Difficulty Starting up
35
Troubleshooting
35
Excessive Oil Consumption/Exhaust Smoke
36
Insufficient Lubrication Pressure
36
Engine Tends to Cut-Off at Full Throttle
36
Engine Tends to Cut-Off at Idle
36
High Fuel Consumption
37
Transmission and Brakes
37
Clutch Grabbing or Performing Inadequately
37
Insufficient Braking
37
Excessive Fuel Consumption
37
Electrical System
38
Battery
38
Turn Signal Lights Malfunction
38
Heavy Steering
38
Noisy Suspension
39
Suspension Oil Leakage
39
Oil Leakage from Suspension
39
Conceptual Diagrams
43
Ignition
43
Headlights and Automatic Starter Section
44
Battery Recharge and Starting
45
Level Indicators and Enable Signals Section
46
Start Permissive Buttons and Level Indicators
46
Turn Signal Lights
47
Turn Indicators and Horn
47
Instruments and Warning Lights Control Board
48
Checks and Inspections
48
4-Pin Connector
48
6-Pin Connector
48
Immobiliser
49
Virgin Circuit
50
Diagnostic Codes
51
Diagnostic Code - 2 Flashes
51
Diagnostic Code - 3 Flashes
52
Ignition Circuit
52
No Spark Plug
53
Pick-Up Inspection
53
H.T. Coil Primary Circuit Inspection
53
HV Coil Secondary Check
53
Pick-Up
54
Multimeter Adaptor - Peak Voltage Detection
54
Battery Recharge Circuit
55
Stator Check
55
Voltage Regulator Check
56
Recharge System Voltage Check
56
Choke Inspection
56
Turn Signals System Check
57
Sealed Battery
58
Dry-Charge Battery
58
Voltage Check up
58
Constant Voltage Battery Charge Mode
58
Commissioning Dry-Charged Batteries
59
Battery Maintenance
59
Electrolyte Level Check
59
Load Status Check
59
Recharging the Battery
60
Battery Cleaning
60
Engine from Vehicle
61
Exhaust Assy. Removal
62
Removal of the Engine from the Vehicle
62
Automatic Transmission
65
Transmission Cover
65
Air Duct
65
Air Duct Filter
66
Removing the Driven Pulley Shaft Bearing
66
Refitting the Driven Pulley Shaft Bearing
67
Removing the Driven Pulley
67
Inspecting the Clutch Drum
67
Removing the Clutch
68
Inspecting the Clutch
69
Pin Retaining Collar
70
Removing the Driven Half-Pulley Bearing
70
Inspecting the Driven Fixed Half-Pulley
71
Inspecting the Driven Sliding Half-Pulley
71
Refitting the Driven Half-Pulley Bearing
71
Refitting the Driven Pulley
72
Inspecting the Clutch Spring
73
Refitting the Clutch
73
Drive-Belt
75
Removing the Driving Pulley
76
Inspecting the Rollers Case
77
Bushing Roller Container
77
Bush Slide Pulley
77
Variable Speed Rollers
77
Refitting the Driving Pulley
79
Refitting the Transmission Cover
80
End Gear
80
Removing the Hub Cover
81
Removing the Wheel Axle
81
Removing the Hub Bearings
81
Removing the Wheel Axle Bearings
82
Inspecting the Hub Shaft
83
Inspecting the Hub Cover
83
Refitting the Hub Cover Bearings
84
Refitting the Hub Bearings
85
Refitting the Ub Cover
85
Flywheel Cover
85
Cooling Hood
85
Cooling Fan
86
Removing the Stator
87
Refitting the Stator
87
Flywheel and Starting
87
Removing the Flywheel Magneto
88
Inspecting the Flywheel Components
88
Refitting the Flywheel Magneto
88
Refitting the Starter Motor
89
Cylinder Assy. and Timing System
89
Removing the Timing System Drive
89
Removing the Cam Shaft
90
Removing the Cylinder Head
91
Removing the Valves
91
Removing the Cylinder - Piston Assy.
92
Inspecting the Small End
92
Inspecting the Wrist Pin
93
Inspecting the Piston
94
Standard Coupling Clearance
94
Maximum Admitted Clearance after Use
94
Inspecting the Piston Rings
95
Removing the Piston
96
Choosing the Gasket
96
Cylinder Base Gasket Thickness
97
Refitting the Piston Rings
98
Refitting the Cylinder
98
Inspecting the Cylinder Head
99
Inspecting the Timing System Components
99
Inspecting the Valve Sealings
100
Inspecting the Valve Housings
100
Inspecting the Valves
101
Inspecting the Springs and Half-Cones
102
Refitting the Valves
103
Inspecting the Cam Shaft
103
Refitting the Head and Timing System Components
104
Crankcase - Crankshaft
108
Splitting the Crankcase Halves
109
Standard Diameter
110
Inspecting the Crankshaft Alignment
111
Inspecting the Crankcase Halves
112
Inspecting the Crankshaft Plain Bearings
113
Refitting the Crankcase Halves
114
Main Bearings
114
Oil Pressure Check
117
Crankshaft Oil Seals
117
Oil Pump Removal
120
Oil Pump Inspection
121
Oil Pump Refitting
122
Removing the Oil Sump
123
Inspecting the By-Pass Valve
123
Refitting the Oil Sump
124
Fuel Supply
124
Removing the Carburettor
125
Refitting the Carburettor
129
Level Check
131
Inspecting the Valve and Needle
133
Inspecting the Automatic Choke Device
134
Adjusting the Idle
136
Suspensions
138
Front Suspension
139
Front Wheel Hub Overhaul
139
Handlebar Removal
139
Front Fork Overhaul
140
Steering Column Refitting
140
Steering Bearing
140
Steering Bearing Upper Race
141
Upper Bearing Washer and Race
141
Lower and Upper Races from Frame
141
Removing the Rear Wheel
142
Refitting the Rear Wheel
142
Shock Absorbers Removal
142
Centre-Stand
142
Changing the Complete Stand
143
Expelling Stand Pivot Pin from Bracket
143
Braking System
144
Rear Brake Calliper Refitting
145
Front Brake Calliper Removal
146
Front Brake Calliper Overhaul
146
Front Brake Calliper Refitting
146
Front Brake Disc Removal
147
Front Brake Disc Refitting
147
Disc Inspection
148
Front Brake Pads Removal
148
Front Brake Pads Refitting
148
Front
149
Recommended Products
149
Front Brake Pump
150
Chassis
152
Seat
153
Side Fairings
153
Rear Rack
154
Driving Mirrors
154
Rear Handlebar Cover
155
Instrument Panel
155
Front Handlebar Cover
156
Headlight Assy.
156
Frame Central Cover
157
Legshield
157
Knee-Guard
158
Removing the Ignition Key-Switch When on *Off*
159
Removing the Ignition Key-Switch When on *Lock*
159
Taillight Assy.
159
Footrest
160
License Plate Holder
160
Air Filter
161
Rear Mudguard
161
Helmet Bay
162
Spoiler
162
Fuel Tank
162
Front Mudguard
163
Top-Case
163
Pre-Delivery
165
Aesthetic Inspection
166
Tightening Torques Inspection
166
Levels Check
167
Road Test
167
Static Test
168
Functional Inspection
168
Time
169
Crankcase
171
Crankshaft
172
Cylinder Assy.
173
Cylinder Head Assy.
174
Rocker Arms Support Assy.
175
Cylinder Head Cover
176
Chain Tensioner
177
Oil Filter
178
Driven Pulley
180
Oil Pump
181
Final Gear Assy.
182
Driving Pulley
183
Starter Motor
184
Flywheel Magneto
185
Belt Cooling Duct
186
Exhaust Pipe
188
Air Cleaner
189
Frame
190
Legshield Spoiler
191
Rear Cover
192
Central Cover
193
Underseat Compartment
194
Plate Holder
195
Mudguard
196
Rear Shock-Absorber
198
Steering Column Bearings
199
Handlebar Covers
200
Handlebar Components
201
Swing-Arm
202
Brake Hoses
203
Front Wheel
206
Grease Tone Wheel or Drive
206
Rear Wheel
207
Electric Devices
208
Electronic Controls
209
Transmissions
210
Index
212

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PIAGGIO Liberty 200 4tempi Workshop Manual (213 pages)

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