PIAGGIO NRG Power Purejet Workshop Manual
  1. Manuals
  2. Brands
  3. PIAGGIO Manuals
  4. Scooter
  5. NRG POWER PUREJET
  6. Workshop manual

PIAGGIO NRG Power Purejet Workshop Manual

Hide thumbs Also See for NRG Power Purejet:
Table of Contents

Advertisement

Quick Links

See also: User Manual
WORKSHOP MANUAL
633265
NRG Power Purejet

Advertisement

Table of Contents
loading

Related Manuals for PIAGGIO NRG Power Purejet

Summary of Contents for PIAGGIO NRG Power Purejet

  • Page 1 WORKSHOP MANUAL 633265 NRG Power Purejet...

  • Page 2: Workshop Manual

    Not all versions 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 WORKSHOP MANUAL NRG Power Purejet This workshop 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 fixing techniques and procedures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS INJ PJ PURE JET INJECTION BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

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

  • Page 9: Vehicle Identification

    NRG Power Purejet Characteristics Vehicle identification Frame prefix: ZAPC45200 ÷ 1001 Engine prefix: C452M Dimensions and mass DIMENSIONS AND MASS Specification Desc./Quantity Max length 1790 mm. Max width 850 mm. Seat height 795 mm. Wheelbase 1280 mm Dry weight 99 kg.
  • Page 10 NRG Power Purejet Characteristics Engine ENGINE Specification Desc./Quantity Engine type 2 stroke single cylinder Piaggio HI-PER2 PRO PUREJET Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 9.4 to 10.4 :1 Throttle body BING Ø18mm Engine idle speed 1800 to 2000 r.p.m.
  • Page 11 NRG Power Purejet Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V belt, automatic clutch, gear reduction unit. Capacities CAPACITIES Specification Desc./Quantity Rear hub oil Quantity: approx. 75 cm³ Mixer oil 1.2 litres Fuel tank capacity 6.5 litres (1.5 litres of reserve)

  • Page 12: Wheels And Tyres

    NRG Power Purejet Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front tyre Tubeless 120/70-13" Rear tyre Tubeless 140/60 x 13'' Wheels With circles of 3.50 x 13" in light alloy. Tightening Torques STEERING ASSEMBLY Name Torque in Nm...

  • Page 13: Engine Unit

    NRG Power Purejet Characteristics Name Torque in Nm Brake reservoir cover fixing screw 2÷4 N·m (Grimeca) - 0,8÷1,5 N·m (Brembo) - 1,5÷2 N·m (Hengtong) Brake pump support fixing screw 7 to 10 Nm Brake fluid pump - hose fitting 13 to 18 Nm...

  • Page 14: Piston Rings

    NRG Power Purejet Characteristics Name Initials Cylinder Piston Play on fitting 1st oversize fitting 40.211-40.218 40.157-40.164 0.047-0.061 1st oversize fitting 40.218-40.225 40.164-40.171 0.047-0.061 2nd oversize fitting 40.397-40.404 40.343-40.35 0.047-0.061 2nd oversize fitting 40.404-40.411 40.35-40.357 0.047-0.061 2nd oversize fitting 40.411-40.418 40.357-40.364 0.047-0.061...
  • Page 15 NRG Power Purejet Characteristics Name Description Dimensions Initials Quantity Half-shaft, trans- 13.75+0.040 clearance E = 0.25 mission side to 0.50 - clearance F = 0.20 to 0.75 Flywheel-side half- 13.75+0.040 clearance E = 0.25 shaft to 0.50 - clearance F = 0.20 to 0.75 Lining between the 40.64...
  • Page 16 NRG Power Purejet Characteristics Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifi- cations AGIP CITY HI TEC 4T Oil for flexible transmission lubri-...
  • Page 17 INDEX OF TOPICS TOOL OOLING...
  • Page 18 NRG Power Purejet Tooling TOOLING Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm ø bear- ings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø...
  • Page 19 NRG Power Purejet Tooling Stores code Description 001467Y017 Bell for bearings, outside Ø 39 001467Y021 Extraction pliers for ø 11 mm bearings 001467Y029 Bell for bearings, O.D. 38 mm 002465Y Pliers for circlips 004499Y Camshaft bearing extractor TOOL - 3...
  • Page 20 NRG Power Purejet Tooling Stores code Description 004499Y007 Half rings 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank-...
  • Page 21 NRG Power Purejet Tooling Stores code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020166Y Pin lock fitting tool 020168Y Water seal punch mount on half- crankcase TOOL - 5...
  • Page 22 NRG Power Purejet Tooling Stores code Description 020169Y Water pump crankshaft fitting and removal spanner 020170Y Water pump/mixer command gear extractor 020171Y Punch for driven pulley roller bearing 020209Y Spring hook 020265Y Bearing fitting base TOOL - 6...
  • Page 23 NRG Power Purejet Tooling Stores code Description 020272Y Piston position check tool 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol 020331Y Digital multimeter TOOL - 7...
  • Page 24 NRG Power Purejet Tooling Stores code Description 020332Y Digital rev counter 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020357Y 32 x 35 mm adaptor 020358Y 37x40-mm adaptor 020359Y 42x47-mm adaptor...
  • Page 25 NRG Power Purejet Tooling Stores code Description 020363Y 20 mm guide 020409Y Multimeter adaptor - Peak volt- age detection 020376Y Adaptor handle 020412Y 15 mm guide 020439Y 17 mm guide 020444Y Test probe removal / fitting tool TOOL - 9...
  • Page 26 NRG Power Purejet Tooling Stores code Description 020456Y Ø 24 mm adaptor 020451Y Start-up crown lock 020452Y Tube for removing and refitting the driven pulley shaft 020460Y Scooter diagnosis and tester 020481Y Control unit interface wiring TOOL - 10...
  • Page 27 NRG Power Purejet Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020469Y Reprogramming kit for scooter diagnosis tester 020614Y Diagnostic tester programming software 020615Y Carbon dam ring fitting kit 020616Y Fuel pressure control kit 020617Y Air pressure check kit...
  • Page 28 NRG Power Purejet Tooling Stores code Description 020620Y Water pump impeller stop 020621Y HV cable extraction adaptor TOOL - 12...

  • Page 29: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 30: Maintenance Chart

    NRG Power Purejet Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change Coolant - change AFTER 1000 KM Action Hub oil - change Oil mixer/throttle linkage - adjustment Odometer cable - greasing Steering - adjustment Brake control levers - greasing...
  • Page 31 NRG Power Purejet Maintenance Action Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See CO regulation in the «Adjusting the engine idle»...
  • Page 32 NRG Power Purejet Maintenance Action Vehicle and brake test - road test (*) See CO regulation in the «Adjusting the engine idle» section AT 30000 KM 130' Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean...

  • Page 33: Spark Plug

    NRG Power Purejet Maintenance Action Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check SAS box (sponge) (**) - cleaning Vehicle and brake test - road test (*) See CO regulation in the «Adjusting the engine idle» sectionp>...
  • Page 34 NRG Power Purejet Maintenance 0,55÷0,65 mm Locking torques (N*m) Spark plug 25 - 30 Nm Hub oil Check Do the following to check the correct level: 1) Stand the vehicle on the centre-stand on flat ground; 2) Remove the dipstick «A», and dry it with a clean cloth.

  • Page 35: Air Filter

    NRG Power Purejet Maintenance Air filter -Remove the cap of the purifier, unscrewing the six clamping screws and removing the filter. Cleaning: -Wash with water and neutral soap. - Dry with a clean cloth and short blasts of com- pressed air.

  • Page 36: Braking System

    NRG Power Purejet Maintenance lined up with the reference mark on the mixer body, as shown in the figure. While doing this, the engine must be fuelled with a 2 % oil mixture (0.5 litre minimum if the reservoir is empty).

  • Page 37: Headlight Adjustment

    NRG Power Purejet Maintenance Top-up Proceed as follows: - 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. CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
  • Page 38 NRG Power Purejet Maintenance 2. Turn on the headlight and check that the bor- derline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and high- er than 7/10;...

  • Page 39: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 40: Poor Performance

    NRG Power Purejet Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Defective fuel pump or damaged depression line...

  • Page 41: Engine Idle

    NRG Power Purejet Troubleshooting Possible Cause Operation recommended at all times. Bear in mind that many problems engines have, derive from the use of the wrong spark plug Intake joint cracked or with a bad seal Replace the intake joint and check its tightness on...
  • Page 42 NRG Power Purejet Troubleshooting Possible Cause Operation If it is not possible to remove any problems by sim- ply adjusting the transmissions, check the brake pads and front brake disc, the brake shoes and the rear drum. If you encounter excessive wear or scoring, make the necessary replacements.

  • Page 43: Noisy Suspension

    NRG Power Purejet Troubleshooting Rear wheel POOR ROAD HOLDING Possible Cause Operation Faulty suspension Check that the rear shock absorber and/or the front fork is/are in good working order. Replace or overhaul the front fork and/or replace the rear shock absorbers in case of malfunction...
  • Page 44 NRG Power Purejet Troubleshooting Possible Cause Operation absence of rust or replace the entire shock ab- sorber. Check that there is no noise or seizing during the wheel rotation; if there is noise or seiz- ing overhaul the final reduction assembly.

  • Page 45: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 46 NRG Power Purejet Electrical system 1. Blinker switch device 2. Front left indicator with lamp 3. Horn button 4. Turn indicator selector. 5. High/low beam selector. 6. Rear brake stop button 7. Complete headlight 8. 2 lamps for parking light 12V-3W 9.
  • Page 47 NRG Power Purejet Electrical system 14.Start button 15.Front right indicator with lamp 16.Key switch 17.Fuel warning light transmitter 18.Oil mix lamp control 19.Voltage regulator 20.H.T. coil 21.Pick-up 22.Magneto 23.Starter motor 24.Front right indicator with lamp 25.Complete resistance 26.Battery 12V-9A 27.Fuse 20A 28.Fuse 5A...
  • Page 48 NRG Power Purejet Electrical system Ignition IGNITION Specification Desc./Quantity Battery 12V - 9Ah Fuse Key switch contacts Voltage regulator Ignition spark plug HV coil Flywheel magneto Pick - up ELE SYS - 4...
  • Page 49 NRG Power Purejet Electrical system Headlights and automatic starter section LIGHTS AND TURN INDICATORS Specification Desc./Quantity Flywheel magneto High beam bulb Type: H8 Power: 12V - 35W Quantity: 1 Digital instrument unit Voltage regulator Low beam bulb Type: H8 Power: 12V - 35W...
  • Page 50 NRG Power Purejet Electrical system Specification Desc./Quantity Key switch contacts Battery 12V - 9Ah Front parking light Type: All glass Power: 12V - 3W Quantity: 2 Turn indicator control device Fuse 5A Turn signal switch 4 turn indicator lamps 12V-10w...
  • Page 51 NRG Power Purejet Electrical system BATTERY CHARGER AND STARTING Specification Desc./Quantity Flywheel magneto Rear light with LED Voltage regulator Starter motor Fuse Key switch contacts Battery 12V - 9Ah Starter remote control Starter button Fuse 5A Fuse 5A Diode Two brake light buttons...

  • Page 52: Digital Instrument Panel

    NRG Power Purejet Electrical system CONSENSUSES AND LEVEL INDICATORS Specification Desc./Quantity Battery 12V - 9Ah Fuse Key switch contacts Water temperature sensor Fuel level sending unit Fuse 5A Mixture oil level sender Digital instrument unit Wheel rpm sensor Digital instrument panel...

  • Page 53: Stator Check

    NRG Power Purejet Electrical system Battery recharge circuit The recharge circuit has a three phase generator with permanent magneto. The generator is directly connected to the voltage regulator. The voltage regulator is connected directly to the earth and battery positive passing through the 15A protection fuse. Therefore this system does not have a connection to the key switch.

  • Page 54: Starter Motor

    NRG Power Purejet Electrical system Recharge system voltage check Connect an ammeter induction clamp to the volt- age regulator positive cable. Measure the battery voltage and turn on the lights with the engine off and wait until the voltage settles at around 12 volts.
  • Page 55 NRG Power Purejet Electrical system Dynamic tests Check the battery voltage after it has not been used for a few hours. Voltage < or equal to 12.5 V. Check the density of the electrolyte of each ele- ment. Bé = 30 ÷ 32 Specific weight: 1.25 ÷...
  • Page 56 NRG Power Purejet Electrical system With the starter motor in no-load, maximum absorption must be 10 A with power supply voltage ≥ 12V. STARTER MOTOR Specification Desc./Quantity Starter motor Voltmeter Starter motor contactor Start button Battery 12V-9Ah Ammeter See also...

  • Page 57: Level Indicators

    NRG Power Purejet Electrical system - To make sure the lamps work, apply a +12V volt- age to the WHITE-BLUE wire of the turn indicator switch for the right lamps and to the PINK wire for the left lamps. See also...
  • Page 58 NRG Power Purejet Electrical system To access the oil mix lamp control remove the right panel. Remember that the +12V voltage to the 2 YELLOW oil mix lamp control lasts 3 minutes from when the key is switched to ON.
  • Page 59 NRG Power Purejet Electrical system WARNING -WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON- TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
  • Page 60 NRG Power Purejet Electrical system Battery maintenance The battery is the electric device that requires the most careful monitoring and diligent maintenance. The maintenance rules are: 1) Check the level of the electrolyte Check regularly that the electrolyte level is at up- per level.
  • Page 61 NRG Power Purejet Electrical system hours. The connections with the power supply source must be made by connecting the corresponding poles (+ with + and - with -). The battery caps must be removed during charging. Specific tooling 020333Y Single battery charger...
  • Page 62 NRG Power Purejet Electrical system ELE SYS - 18...

  • Page 63: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 64 NRG Power Purejet Engine from vehicle Removal of the engine from the vehicle 1. Detach the battery. 2. Remove the exhaust assy. 3. Remove the rear wheel. 4. Remove the rear brake cable. 5. Detach the electrical connection to the fly- wheel.
  • Page 65 INDEX OF TOPICS NGINE...

  • Page 66: Automatic Transmission

    NRG Power Purejet Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.

  • Page 67: Removing The Driven Pulley

    NRG Power Purejet Engine Refitting the driven pulley shaft bearing -Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside. N.B. WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

  • Page 68: Removing The Clutch

    NRG Power Purejet Engine Removing the clutch - Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and put the central screw under stress. CAUTION THE TOOL WILL BE DEFORMED IF THE CEN- TRAL SCREW IS TIGHTENED UP TOO FAR.
  • Page 69 NRG Power Purejet Engine Pin retaining collar - Remove the collar with the aid of 2 screwdrivers. - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley.
  • Page 70 NRG Power Purejet Engine Inspecting the driven fixed half-pulley - Check that there are no signs of wear on the work surface of the belt. If there are, replace the half- pulley.. - Make sure the bearings do not show signs of un- usual wear.

  • Page 71: Refitting The Driven Pulley

    NRG Power Purejet Engine - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole.
  • Page 72 NRG Power Purejet Engine • Measure the free length of the mobile driving half- pulley. Characteristic Standard length: 110 mm Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation...

  • Page 73: Removing The Driving Pulley

    NRG Power Purejet Engine Nut locking clutch unit on pulley 55 ÷ 60 Nm Refitting the driven pulley • Refit the driven pulley assembly, the clutch bell and the nut using the specific tool. Specific tooling 020565Y Flywheel lock calliper spanner Locking torques (N*m) Locking torque: 40 ÷...
  • Page 74 NRG Power Purejet Engine Inspecting the rollers case 1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation. 2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary).
  • Page 75 NRG Power Purejet Engine Refitting the driving pulley - Manually move the mobile driven half-pulley away pulling it towards the clutch unit and insert the belt repeating the direction of rotation of the first fitting. N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE...
  • Page 76 NRG Power Purejet Engine Removing the hub cover • Remove the transmission cover • Remove the clutch assembly • Discharge the rear hub oil. • Remove the 5 screws indicated in the figure. • Remove the hub cover with driven pulley shaft.

  • Page 77: Removing The Driven Pulley Shaft Bearing

    NRG Power Purejet Engine Removing the driven pulley shaft bearing - Remove the seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane. - Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.
  • Page 78 NRG Power Purejet Engine Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the specific tool posi- tioned under the press and insert the driven pulley axle.

  • Page 79: Flywheel Cover

    NRG Power Purejet Engine Refitting the ub cover • Refit the complete wheel axis. • Refit the intermediate gear being careful of the two shim adjustments. • Apply LOCTITE 510 for surfaces on the hub cov- er and refit it with the complete pulley shaft.
  • Page 80 NRG Power Purejet Engine • Use a specific extractor to remove the flywheel Specific tooling 020162Y Flywheel extractor • Remove the two studs of the revolutions sensor to the coolant inlet pipe. • Remove the coolant inlet duct • Remove the two stator fixing screws •...
  • Page 81 NRG Power Purejet Engine Refitting the flywheel cover • Fit the rubber seal on the flywheel con- nector and around the inlet coolant hose. • Keeping the flywheel connector rubber clamp on the coolant inlet hose, refit the flywheel cover paying attention in inserting the strap in the groove.

  • Page 82: Removing The Cylinder Head

    NRG Power Purejet Engine Removing the cylinder head • Use a TORX 20 wrench to remove the air feeding line from the injection head as shown in the figure. • Remove the injection head, including the fuel in- jector and the pressure regulator, using the 2 screws shown in the figure •...
  • Page 83 NRG Power Purejet Engine • Remove the coolant outlet union from the head with the relevant O-ring, using the two screws, as shown in the figure. • Remove the head inside recirculation duct as shown in the figure. • Remove the head using the 4 screws as shown in the figure.
  • Page 84 NRG Power Purejet Engine Removing the cylinder - piston assy. • Remove the cylinder holding the piston in order to prevent damage • Remove the 2 plug stops by a screwdriver inser- ted into the special slits on the piston •...

  • Page 85: Inspecting The Small End

    NRG Power Purejet Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER AL- LOWED, SHOWS SIGNS OF WEAR OR OVER- HEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND...
  • Page 86 NRG Power Purejet Engine - Measure the outer diameter of the piston, per- pendicular to the pin axis. - Take the measurement in the position shown in the figure To classify the cylinder-piston fitting, check the ap- propriate table See also Cylinder - piston assy.

  • Page 87: Removing The Piston

    NRG Power Purejet Engine Removing the piston • Insert the roller in the connecting rod • Fit piston and wrist pin on the connecting rod, with piston facing the outlet • Insert the wrist pin stop ring in the specific tool...
  • Page 88 NRG Power Purejet Engine • Fit the wrist pin stop using the plug as shown in the figure Specific tooling 020166Y Pin lock fitting tool Choosing the gasket • Temporarily fit the cylinder on the piston, without the basic gasket.
  • Page 89 NRG Power Purejet Engine Refitting the head and timing system components • Carefully clean the head, removing any carbon residues • Check the perfect condition of the fitting surfaces • Check that the O-rings are not broken, otherwise replace them •...

  • Page 90: Air Injection

    NRG Power Purejet Engine • Refit the dust cover onto the air injector. N.B. NOTE THAN WHEN THE AIR INJECTOR IS RE- FITTED, THE CARBON DAM O-RING MUST BE NEW. IF A NEW AIR INJECTOR IS FITTED, THE NEW CARBON DAM RING IS ALREADY PRESENT.

  • Page 91: Crankcase - Crankshaft

    NRG Power Purejet Engine - Remove the air injector - The carbon dam ring must be broken to be re- moved. - Carefully clean the air injector and the seat re- moving any carbon residues. - Check that the sealing rings exhibit no wear, or replace them.
  • Page 92 NRG Power Purejet Engine - Remove the throttle body with manifold, diaphragm, gasket and blade support - Remove the volumetric compressor - Remove the thermal unit - Remove the starter See also Removing the driven pulley Removing the driving pulley Cylinder assy.

  • Page 93: Removing The Crankshaft

    NRG Power Purejet Engine - Install the specific tool with relevant guard on the transmission side crankcase half. Use four M6 screws of a suitable length. - Use a 17 mm Allen wrench to remove the crank- shaft from the transmission side crankcase half.
  • Page 94 NRG Power Purejet Engine - Use the specific tool to remove any bearings left on both crankcase halves. Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing Refitting the crankshaft bearings - This operation requires assembly by temperature - Dip the bearings in oil bath when this is still cold.
  • Page 95 NRG Power Purejet Engine 008119Y009 Tube to assemble shafts and axles Inspecting the crankshaft components - Check for any abnormal wear on the eccentric track. - To check using the dial gauge, see the section «Checking crankshaft alignment» Inspecting the crankshaft alignment With the specific tool shown check that the eccen- tricity of the surfaces of diam.
  • Page 96 NRG Power Purejet Engine Inspecting the crankcase halves - Remove the oil seals from both crankcase halves using a screwdriver. - Clean the fitting surfaces removing Loctite resi- dues and residues of the paper seal on the cylin- der. - For this operation, use specific products available on the market.
  • Page 97 NRG Power Purejet Engine Refitting the crankshaft - Place the transmission side crankcase half on two wooden supports. - Refit the water pump rotor (note that the thread- ing is anticlockwise) - Use the thermal gun to heat the bearing seat to approx.
  • Page 98 NRG Power Purejet Engine - Prepare the fitting surface using the recommen- ded product applying a thin layer after degreasing the surface with a suitable solvent (e.g. trichloro- ethylene) Recommended products Loctite 510 Liquid sealant Gasket - Assemble the equipment need to close the crank- case half (screws, wrench).
  • Page 99 NRG Power Purejet Engine Refitting the crankcase halves - Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur- face using a suitable solvent (e.g. trichloroethy- lene) - Heat the flywheel-side half crankcase with a ther- mal gun.
  • Page 100 NRG Power Purejet Engine Air compressor Removal Air compressor removal - Remove the throttle body manifold - Remove the air piping union from the injection head using a Torx 25mm wrench - Remove the air piping support bracket fixing screw from the transmission covers.
  • Page 101 NRG Power Purejet Engine Overhaul Air compressor check - Check the presence of any unusual wear, traces of overheating on the roller contacting with the ec- centric, as shown in the figure. - Use a feeler gauge to measure the axial play of the control roller by placing the blade between roller and one of the two shim adjustments.
  • Page 102 NRG Power Purejet Engine - Place the shaft with the eccentric at its lower dead point. - Insert the compressor into the crankcase, cor- rectly placing the reference dowels. - Refit the sealing ring. - Refit the 4 fixing screws tightening to the prescri- bed torque.

  • Page 103: Crankshaft Oil Seals

    NRG Power Purejet Engine Crankshaft oil seals Refitting - Install a new oil seal on the flywheel side using the specific tool punch. The flywheel side oil seal can be recognised by the smaller diameter. N.B. USE OF THE TOOL IS NOT COMPATIBLE WITH...
  • Page 104 NRG Power Purejet Engine Removal - Remove the transmission cover - Remove driving pulley - Remove the 2 screws shown in the figure - Remove the pipe gasket from the case as shown in the figure - Remove the pipe from the oil inlet union in the...
  • Page 105 NRG Power Purejet Engine Refitting - To refit, perform the removal procedures in the reverse direction. - Perform purging after refitting, using the screw shown in the figure. ENG - 41...
  • Page 106 NRG Power Purejet Engine ENG - 42...

  • Page 107: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 108: Removing The Front Wheel

    NRG Power Purejet Suspensions Sospensioni anteriore This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Support the vehicle in such a way that the front wheel is raised. - Using two 18 mm hexagonal wrenches remove the front wheel axle.

  • Page 109: Front Fork

    NRG Power Purejet Suspensions Refitting When refitting, tighten to the prescribed torque and apply the recommended grease to the threaded cone. 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 °...
  • Page 110 NRG Power Purejet Suspensions - Remove screw 1 fixing the screw to the stem and remove the stanchion heating it if necessary with the specified heater, then remove sealing ring 2 and seeger 3. - Using nut 4, remove the spring stem and bushing.

  • Page 111: Steering Column

    NRG Power Purejet Suspensions Rod disassembly - Remove the dust guard (1) using a screwdriver to prise it out. - Remove the seeger (2) and remove the power pipe. N.B. GREASE THE SPRINGS AND THE BUSHINGS BEFORE REFITTING, WITH A SMALL QUANTI- TY OF GREASE (AROUND 3 GR.)

  • Page 112: Steering Bearing

    NRG Power Purejet Suspensions - Only remove the seats if it is strictly necessary. - Using the special tool remove the upper fifth wheel seat by putting the special tool into the lower part of the headstock as indicated in the figure.
  • Page 113 NRG Power Purejet Suspensions Overhaul slew ring seat on fork Check the condition of the fifth wheel and the fifth wheel seat on the fork (steering tube). Replace if there are faults. - Support the fork properly. - Using the special tool, remove the fifth wheel seat on the steering tube as shown in the photograph by applying small mallet blows.

  • Page 114: Removing The Rear Wheel

    NRG Power Purejet Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFIT- TING.

  • Page 115: Centre-Stand

    NRG Power Purejet Suspensions Centre-stand Assembly and staking of stand pivot pin to bracket - Caulk the end of the pin «P» between the two punches shown in the figure. - After caulking it must be possible for the stand to turn freely.
  • Page 116 NRG Power Purejet Suspensions SUSP - 10...
  • Page 117 INDEX OF TOPICS INJ PJ PURE JET INJECTION...
  • Page 118 NRG Power Purejet pure jet injection Introduction EMS injection system The injection system has an incorporated injection and ignition. Injection is direct and pneumatic, by air electro-injector and fuel electro-injector. Injection and ignition are phased on the 2T cycle by a phonic wheel on the flywheel and phase rpm sensor with reluctance variation.

  • Page 119: Precautionary Measures

    NRG Power Purejet pure jet injection - Fuel consumption reduction - Lubricant consumption reduction - Discharge emission reduction. Emissions are further limited by the catalyser. The injection system allows these results by: Air washing of cycle 2T - Stratified load...

  • Page 120: Troubleshooting

    NRG Power Purejet pure jet injection 9. To prevent damage, disconnect and reconnect the ECU system connectors only if required. Before reconnecting, check that the connectors are dry. 10. During electrical checks, do not force the tester tips into the connectors. Do not perform tests not specifically required by the manual.
  • Page 121 NRG Power Purejet pure jet injection Fuel supply vent clogged 5. Ignition system Faulty spark plug Faulty coil Faulty screened cap 6. Suction circuit Air filter dirty 7. Others Incorrect reset of the gas valve position sensor 2 Injection system faults may be caused by loosened connectors. Make sure that all connections are efficient.
  • Page 122 NRG Power Purejet pure jet injection 6. The diagnostic tester is ready for use. The selected software will stay in memory also for the next uses N.B. IF THE SCOOTER DIAGNOSTIC TESTER IS NOT LOADED WITH THE SYSTEM SOFTWARE, UP- GRADE WITH A PC, THE PROGRAMMING KIT AND THE SOFTWARE TO LOAD.

  • Page 123: Engine Rpm

    NRG Power Purejet pure jet injection • Remove the cover from the diagnostic grip • Connect the diagnostic tester wiring • Connect the power supply cable with battery ter- minals to the diagnostic tester • Connect the terminals to the battery respecting the polarity: RED (+) - BLACK (-) N.B.

  • Page 124: Engine Status

    NRG Power Purejet pure jet injection Specification Desc./Quantity VOLTAGE SENSOR V Denotes the voltage of the TPS sensor TEMP. ENGINE V Denotes the voltage of the coolant temperature in- dicator TPS1 OUTPUT V Indicates the TPS1 voltage indicator TPS2 OUTPUT V...
  • Page 125 NRG Power Purejet pure jet injection Specification Desc./Quantity Flashing light G21 P1124 TPS1 OFFSET TPS1 signal is not as expected. Light off G21 P1125 TPS1 TPS1 signal missing. Voltages close to 0V (short circuit) Voltages close to 5V (open circuit)
  • Page 126 NRG Power Purejet pure jet injection Specification Desc./Quantity G60 P1160 Air injector The ECU has detected an interruption in the injec- tor circuit. The fault can only be recognised in the presence of phase - rpm Light on Faults are reported by a dark dot on one of the reference columns.
  • Page 127 NRG Power Purejet pure jet injection This function is very useful for making an efficiency check of the main components of the system and related circuits. The components involved are: ACTIVE DIAGNOSTICS Specification Desc./Quantity AIR INJECTOR Wait for the sound confirming 5 openings...
  • Page 128 NRG Power Purejet pure jet injection terminal layout on cpu 1 - Ground 3 - Fuel injector (negative) 4 - To diagnosis indicator (negative) 5 - Coolant temperature indicator (button negative) 6 - Analogue rev. counter signal 7 - Signal TPS 1...
  • Page 129 NRG Power Purejet pure jet injection 21 - Serial line for diagnostic tester EMS system diagram INJ PJ - 13...

  • Page 130: Ems System

    NRG Power Purejet pure jet injection SYSTEM Specification Desc./Quantity Digital instrument unit Fuse 5A Key switch contacts EMS diagnostic socket Fuel pump Battery 12V - 9Ah Fuse Air injector Throttle position sensor HV coil Flywheel magneto Voltage regulator Fuel injector...
  • Page 131 NRG Power Purejet pure jet injection cpu power circuit ECU POWER SUPPLY CIRCUIT Specification Desc./Quantity Digital instrument unit INJ PJ - 15...
  • Page 132 NRG Power Purejet pure jet injection Specification Desc./Quantity Fuse 5A Fuel pump Key switch contacts Fuse Battery 12V - 9Ah Air injector HV coil Voltage regulator Fuel injector Injection ECU 1-Turn the key switch to the «ON» position Check the following conditions: - Ignition light on steady - Fuel pump activated for approx.
  • Page 133 NRG Power Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 10- Measure the battery voltage. GO TO point 11 GO TO point 12 11- Voltage is lower than 8.5 V. Recharge the battery. GO TO point 15 12- The battery voltage is between 8.5 and 14.5 V...
  • Page 134 NRG Power Purejet pure jet injection 21- Check on the ground connection. Check the ground connection on pin n°1 by using the multimeter. 1 - battery positive = battery voltage YES point 22 NO point 23 22- The ground line is efficient.
  • Page 135 NRG Power Purejet pure jet injection 30- Restore the wiring insulation. GO TO point 29 31- Connect the specific tool to the ECU. Mount a new 20A fuse. Check the presence of battery volt- age between pin 15 and pin 1 ( the fuse does not...
  • Page 136 NRG Power Purejet pure jet injection - Remove the 2 5 A fuses - Remove the connector of the fuel pump GO TO point 41 Specific tooling 020481Y Control unit interface wiring 41- Remove the burnt 20A fuse. Check the mass insulation of the supply line of pin 17 with the switch on «ON»...

  • Page 137: Components Layout

    NRG Power Purejet pure jet injection diagnosis tester connection circuit COMPONENTS LAYOUT: 1 ECU 2 Diagnostic outlet A + Under-panel B + Fixed Connect the scooter diagnostic tester. Enter the main menu and select a function. If the diagnostic tester returns «ECU not responding, check connections», proceed as follows.
  • Page 138 NRG Power Purejet pure jet injection GO TO point 5 5. Disconnect tester from diagnostic connector. Check the continuity of the ground line between diagnostic connector and vehicle mass. Diagnostic connector Pin «2» - Battery negative = continuity YES point 7 NO point 6 6.
  • Page 139 NRG Power Purejet pure jet injection Injection lamp circuit THERMIC: 1 - 4 CONDITIONS: Key selector set to «ON», engine off STANDARD:Less than 0.1 V THERMIC: 1 - 4 CONDITIONS: Key selector set to "ON", engine on, no fault detected...
  • Page 140 NRG Power Purejet pure jet injection INJECTION LAMP CIRCUIT Specification Desc./Quantity Digital instrument unit Fuse 5A Key switch contacts Fuel pump Injection ECU INJ PJ - 24...

  • Page 141: Check Lamp

    NRG Power Purejet pure jet injection Specification Desc./Quantity Fuse Battery 12V - 9Ah The injection lamp must go on every time «ON» is switched on and remain on until the engine is started. When the autodiagnosis detects a fault, it turns on the lamp based on the level of priority: •...
  • Page 142 NRG Power Purejet pure jet injection 5- Remove the 5A fuse (white lead) and check the presence of voltage. 1 - 4 = 0V YES point 6 NO point 7 6. The lamp control circuit is efficient. 7. Access the instrument unit and disconnect the 8-pin connector.
  • Page 143 NRG Power Purejet pure jet injection 13. Battery voltage is missing and the lamp is on. Access the instrument unit and disconnect the 8- pin connector. Check the ground insulation of the connection line 1 - 4 > 1MOhm In case of faults, restore the wiring.
  • Page 144 NRG Power Purejet pure jet injection THROTTLE POSITION SENSOR CIRCUIT (T.P.S.) Specification Desc./Quantity Key switch contacts Fuse Battery 12V - 9Ah Injection ECU Coolant temperature sensor Valve position sensor The throttle position sensor (TPS) is a built-in part of the throttle body and cannot be removed. The sensor receives 5V power (electronically determined) from the ECU.
  • Page 145 NRG Power Purejet pure jet injection The throttle position sensor and related circuit can be checked by using the scooter tester. Specific tooling 020460Y Scooter diagnosis and tester For the check, proceed as follows. Connect the diagnostic tester to the vehicle. Select the «parameters» function. The following values are reported: THROTTLE OPEN.
  • Page 146 NRG Power Purejet pure jet injection - ON to allow switching to the stored sta- tus. P1125 TPS1 signal missing. Acknowledge- Free TPS1 ment occurs when the signal voltage is close to: 0V = short circuit 5V = open circuit P1128 TPS2 signal missing.
  • Page 147 NRG Power Purejet pure jet injection GO TO point 2 2. Use a multimeter to check the wiring continuity. N° 1 (TPS) - 16 (ECU) = Ohm Continuity N° 2 (TPS) - 7 (ECU) = Ohm Continuity N° 3 (TPS) - 10 (ECU) = Ohm Continuity N°...
  • Page 148 NRG Power Purejet pure jet injection 16(-) - 18(+) = 5 V YES point 12 NO point 11 11. Carefully check the ECU power supply. Re- place the ECU if required. GO TO point 10 12. Connect the TPS sensor connector and meas- ure the voltage.

  • Page 149: Automatic Reset

    NRG Power Purejet pure jet injection 17. When slightly different voltage values are found, check the ECU connector more thoroughly and replace the ECU if required. 18. TPS sensor and circuit meet specs. See also menù diagnosis tester T.P.S. signal reset The throttle body is supplied with gas valve and is precalibrated.

  • Page 150: Manual Reset

    NRG Power Purejet pure jet injection A greater tensioning causes signals TPS1 and TPS2 whose voltage is not as expected by the ECU, which cancels the reset procedure. To check that TPS signals are properly reset, use the following procedure: 1- Connect the scooter diagnostic tester Select the «parameters»...
  • Page 151 NRG Power Purejet pure jet injection - The control transmission is properly installed and adjusted Proceed to manually reset the signals TPS1 and TPS2 as follows: 1- Connect the scooter diagnostic tester Select «RESET TPS» from the menu. By using this procedure, the following indications are visualised.
  • Page 152 NRG Power Purejet pure jet injection Press a key GO TO point 14 14. Wait GO TO point 15 15. TPS resetting successful Press a key GO TO point 16 16. The manual procedure is completed. For a further confirmation, check that the indications reported in the parameters function comply with the instructions given for automatic reset.
  • Page 153 NRG Power Purejet pure jet injection RPM-TIMING SENSOR Specification Desc./Quantity Fuse Battery 12V - 9Ah Key switch contacts Pick - up Injection ECU This built-in injection and ignition system, requires a prompt perception of the rotation speed and angular position of the crankshaft. With each engine cycle the ECU, must manage the following, in order: •...
  • Page 154 NRG Power Purejet pure jet injection GO TO point 4 3. The ECU has detected no fault relating to the phase - rpm signal. The signal may be totally missing. To check, proceed as follows. GO TO point 4 4. Connect the interface wiring. Omit the connection to the ECU. Disconnect the connector from the flywheel magneto.
  • Page 155 NRG Power Purejet pure jet injection 8. Restore the insulation or replace the wiring. GO TO point 7 9. Check the reciprocal insulation of the lines 19 - 20 > 1MOhm YES point 11 NO point 10 10. Restore the insulation or replace the wiring.
  • Page 156 NRG Power Purejet pure jet injection 12. Restore the insulation or replace the wiring. GO TO point 11 13. Connect the flywheel connector and repeat the insulation checks from earth and from positive. 1 - 19 > 1MOhm 1 - 20 > 1 MOhm YES point 15 NO point 14 14.
  • Page 157 NRG Power Purejet pure jet injection 18. Check the magnetic activity and gap of the phase - rpm sensor. Replace the stator if required. GO TO point 17 19. Connect the interface wiring to the ECU. Check the alternated voltage upon start up and at idle.
  • Page 158 NRG Power Purejet pure jet injection PETROL INJECTION CIRCUIT Specification Desc./Quantity Key switch contacts Fuse Injection ECU Air injector Battery 12V - 9Ah HV coil Fuel injector The ignition system with built-in injection is an induction type. Ignition is managed based on two pa- rameters: •...
  • Page 159 NRG Power Purejet pure jet injection The ECU autodiagnosis also checks the coil power circuit and detects interruptions and shorts. Check- ing is normally only done in the presence of the rpm - timing signal (engine running). Any faults are signalled to the driver via the injection lamp.
  • Page 160 NRG Power Purejet pure jet injection - Uncertain contacts - Lacking insulation CHECKING THE ELECTRIC CIRCUIT 1. Connect the interface wiring. Do not connect the ECU. Disconnect the connector of the H.V. coil primary. GO TO point 2 Specific tooling 020481Y Control unit interface wiring 2.
  • Page 161 NRG Power Purejet pure jet injection 7. Restore the wiring GO TO point 6 8. Check the insulation - from negative - of the control line of the coil. 1 - 12 > 1MOhm NO point 9 GO TO point 10 9.
  • Page 162 NRG Power Purejet pure jet injection 15. Replace the screened cap. GO TO point 14 16. Reconnect the following components: - Shielded cap - H.V. coil supply connector - ECU interface wiring: GO TO point 17 17. With the engine idle, measure the induced voltage produced by the H.V.

  • Page 163: Ignition Timing Check

    NRG Power Purejet pure jet injection ignition timing check The ignition advance is electronically determined on the basis of the ECU parameters. For this rea- son, it is not possible to state reference values based on the engine rpm. The ignition advance value can be detected by the parameters function of the diagnostic tester.

  • Page 164: Compressed Air System

    NRG Power Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light for timing control 020621Y HV cable extraction adaptor compressed air system Direct injection in the cylinder takes place by pressure of the compressed air. The injection pressure is vital to ensuring the correct fuel preparation and pulverisation of the mix.
  • Page 165 NRG Power Purejet pure jet injection 4- The engine rpm and pressures are lower than specifications. Check the battery and starter sys- tem. GO TO point 3 5- Engine rpm and pressure are as expected. Check that the pressure remains stable over time.
  • Page 166 NRG Power Purejet pure jet injection 13- Bring the system to pressure again and as soon as the starter stops rotating, close the com- pressor connection pipe at the shunting with the manometer by a flat and long pincer. Check the pressure progress.
  • Page 167 NRG Power Purejet pure jet injection AIR INJECTOR Specification Desc./Quantity Key switch contacts Fuse Battery 12V - 9Ah Air injector HV coil Voltage regulator Injection ECU Fuel injector The air injector is the main component of the electrical-pneumatic injection. To make things easier, the injector is called an air injector, even if a mixture of air and petrol is actually injected.
  • Page 168 NRG Power Purejet pure jet injection the air injector circuit. A fault is detected if the circuit is interrupted or if there is a short towards the earth or positive. Any faults are signalled to the driver via the injection lamp. If a fault is present the engine will not run.
  • Page 169 NRG Power Purejet pure jet injection 11 - Check the battery positive voltage to the blue lead of the power supply connector of the air in- jector. 1 - blue lead (positive) = V battery YES point 13 NO point 12 N.B.
  • Page 170 NRG Power Purejet pure jet injection 18- Restore the wiring. TO GO point 17 19- Check the air injector winding resistance standard value= ... Ohm YES point 21 NO point 20 20- If very different resistive values are detected, replace the air injector.
  • Page 171 NRG Power Purejet pure jet injection 25 - The air injector control circuit is efficient. The air injector opening time can be checked when the engine is running by the «parameters» menu AIR INJECTION T. mS = 6 ÷ 7 mS (start up at 20° C) ~ 1.6 mS (idle at 20°...

  • Page 172: Fuel Pump Circuit

    NRG Power Purejet pure jet injection FUEL PUMP CIRCUIT Specification Desc./Quantity Fuel pump Key switch contacts Injection ECU Fuse Battery 12V - 9Ah The fuel pump is a piston type supplied with a di- rect current motor. It is designed to distribute high...
  • Page 173 NRG Power Purejet pure jet injection and get rid of the fuel aged by boiling within the injector support. Subsequent management of the pump is combined with the presence of the rpm timing signal. This guarantees the safety of the ve- hicle in the event of an accident.
  • Page 174 NRG Power Purejet pure jet injection 8- The fuel pump was activated 10 times and the tester returned the «test successfully completed» outcome. The pump and the relative circuit are currently efficient. For greater certainty, proceed with the auto-diagnostic check in order to highlight any errors in stored status.
  • Page 175 NRG Power Purejet pure jet injection 17- Check the efficiency of the 20 A fuse, the key switch and restore the wiring if necessary. 18- Check the continuity of the petrol pump control line. 14 - green/blue (pump con.) = continuity N.B.
  • Page 176 NRG Power Purejet pure jet injection If there are difficulties in doing the check directly on the pump, proceed with the check through the wiring. Reconnect the fuel pump connector and measure the resistance between the specific tool's pins, keeping the switch in the «OFF» position.
  • Page 177 NRG Power Purejet pure jet injection petrol injector circuit TERMINALS: 1 - 3 CONDITIONS: Engine stopped, switch in any position STANDARD VALUES: Battery voltage PETROL INJECTION CIRCUIT Specification Desc./Quantity Key switch contacts Fuse Injection ECU Air injector Battery 12V - 9Ah...
  • Page 178 NRG Power Purejet pure jet injection petrol injection has finished. The operation of the petrol injector is always very important in all engine operating phases, but particularly during idling and starting. The ECU autodiagnosis also checks the petrol injector control circuit. A fault is detected if the circuit is interrupted or if there is a short towards the earth or positive.

  • Page 179: Coolant Temperature Sensor

    NRG Power Purejet pure jet injection coolant temperature sensor circuit COOLANT TEMPERATURE SENSOR Specification Desc./Quantity Digital instrument unit Key switch contacts Fuse 5A Fuse Battery 12V - 9Ah Injection ECU Coolant temperature sensor INJ PJ - 63...
  • Page 180 NRG Power Purejet pure jet injection INJ PJ - 64...

  • Page 181: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 182: Front Brake Calliper

    NRG Power Purejet Braking system Front brake calliper Removal • Check that the brake piping, gasket and fitting are in good condition. If you see any oil on the brake calliper and/on the components of the system, it is necessary to replace them.

  • Page 183: Front Brake Disc

    NRG Power Purejet Braking system 1 DUST GUARDS 2 SEALING RINGS 3 PLUNGERS 4 O-RING GASKET Refitting • Refit the pincer on the support and tighten the screws at the prescribed torque. • Refit the tube complete with fitting with new copper gaskets.

  • Page 184: Disc Inspection

    NRG Power Purejet Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring. Characteristic New rear disc thickness 4.0 mm...
  • Page 185 NRG Power Purejet Braking system Removal • Remove the pin split ring located at the back of the calliper body. • Remove the pin, paying attention in re- covering the spring, hence remove the pads. • The pads must be replaced if the work- ing thickness is less than 1.5 mm...
  • Page 186 NRG Power Purejet Braking system Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in...
  • Page 187 NRG Power Purejet Braking system THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE OIL ON IT. Specific tooling 020329Y MityVac vacuum-operated pump Recommended products AGIP BRAKE 4 Brake fluid...
  • Page 188 NRG Power Purejet Braking system 8 - Spring CAUTION - THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAK- ING EFFICIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY SOL- VENT.

  • Page 189: Cooling System

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 190 NRG Power Purejet Cooling system System bleed 1. Fill the circuit through the expansion tank to the maximum level. 2. Fasten the rubber line to the drain fitting on the head and thread it into the expansion tank mouth.. 3. Loosen the fitting and restore the tank level.
  • Page 191 NRG Power Purejet Cooling system - Remove the mixer/water pump drive-belt with the two sprockets - Remove the split ring from the shaft together with the bearings - Remove the steel washer - Using the air heater, warm up the crankcase in the area around the water pump bearings as shown in the picture.
  • Page 192 NRG Power Purejet Cooling system - Ensure the shaft is not abnormally worn and the bearings not noisy. Otherwise, replace shaft and bearings - Carefully clean oil seal and bearing housings - Use a new oil seal to refit - Position the new oil seal on the special tool with...
  • Page 193 NRG Power Purejet Cooling system Using the air heater, warm up the water pump bearing housing, without directing the air flow di- rectly against the oil seal - Lubricate the end of the water pump shaft on the oil seal side, using the recommended product.
  • Page 194 NRG Power Purejet Cooling system TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER. Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check: Opening start temperature 60±2°C Refitting • Refit the thermostat onto the head, fol-...
  • Page 195 INDEX OF TOPICS CHAS HASSIS...
  • Page 196 NRG Power Purejet Chassis Frame central cover • Remove the top and bottom fairings. • Remove the 2 Philips screws fixing the footrest. • Remove the 3 Allen screws located around the fuel filler cap. • Remove the fuel filler cap.
  • Page 197 NRG Power Purejet Chassis Footrest • Remove the centre frame cover. • Remove the 10 screws (5 for each side), hence remove the footrest. • Remove the side fairing from the foot- rest, by removing the two screws join- ing this to the spoiler and the knee- guard.
  • Page 198 NRG Power Purejet Chassis • Remove the lower fairings, removing the 2 side screws and the central join- ing screw located underneath the spark plug cover. License plate holder • Remove the top fairing joining element located behind the taillight.
  • Page 199 NRG Power Purejet Chassis • Remove the metallic clip joining the rubber bellow to the tank and loosen the 3 screws fixing to the knee-guard • Remove the 2 top screws fixing the tank to the frame and lower the tank so to disconnect the inlet and outlet fuel hoses from the pump.
  • Page 200 NRG Power Purejet Chassis CHAS - 6...
  • Page 201 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 202 NRG Power Purejet Pre-delivery Aesthetic inspection Appearance checks: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...
  • Page 203 NRG Power Purejet Pre-delivery 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 THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.

  • Page 204: Static Test

    NRG Power Purejet Pre-delivery 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 205 INDEX OF TOPICS TIME...
  • Page 206 NRG Power Purejet Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replace- ment TIME - 2...
  • Page 207 NRG Power Purejet Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replace- ment TIME - 3...
  • Page 208 NRG Power Purejet Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001118 Main bearings - Replacement 001099 Oil seal, flywheel side - Re- placement 001100 Oil seal, clutch side - Re- placement TIME - 4...

  • Page 209: Cylinder Assy

    NRG Power Purejet Time Cylinder assy. YLINDER PISTON Code Action Duration 001002 Cylinder piston - Replace- ment 001107 Cylinder / piston - Inspection / cleaning TIME - 5...

  • Page 210: Cylinder Head Assy

    NRG Power Purejet Time Cylinder head assy. HEAD UNIT Code Action Duration 001013 Intake manifold - Replace- ment 001056 Head gasket - change 001057 Thermostat - Replacement 001093 Spark plug - Replacement 001126 Head - Replacement 007010 Bleed valve - Replacement...

  • Page 211: Driven Pulley

    NRG Power Purejet Time Driven pulley RIVEN PULLEY Code Action Duration 001110 Driven pulley - Replacement 001022 Clutch - Replacement 001155 Clutch bell housing - Re- placement 001012 Driven pulley - overhaul TIME - 7...
  • Page 212 NRG Power Purejet Time Oil pump IL MIX PUMP Code Action Duration 001018 Mixer - Replacement 001019 Mixer belt - replacement 001028 Mix movement gear socket - Replacement TIME - 8...
  • Page 213 NRG Power Purejet Time Final gear assy. INAL REDUCTION GEAR Code Action Duration 001010 Geared reduction unit - Serv- 001156 Gear reduction unit cover - Replacement 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replace- ment TIME - 9...

  • Page 214: Driving Pulley

    NRG Power Purejet Time Driving pulley RIVING PULLEY Code Action Duration 001011 Driving belt - Replacement 001066 driving pulley - Replacement 001017 Starter sprocket wheel - Re- placement 001086 Driving half-pulley - replace 001177 Variator rollers / shoes - Re-...

  • Page 215: Transmission Cover

    NRG Power Purejet Time Transmission cover RANSMISSION COVER Code Action Duration 001096 Transmission crankcase cov- er - Replacement 001131 Transmission air intake - Re- placement 001132 Transmission air inlet pipe - Replacement 001135 Transmission cover bearing - Replacement 004179 Stand buffer - Replacement...

  • Page 216: Water Pump

    NRG Power Purejet Time Water pump ATER PUMP Code Action Duration 001113 Water pump - Replacement 001062 Water pump command shaft - Replacement 007019 Connection water pump pipe / return pipe - Replace- ment TIME - 12...
  • Page 217 NRG Power Purejet Time Starter motor STARTER MOTOR Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Replacement 001017 Start-up pinion - Replace- ment TIME - 13...

  • Page 218: Flywheel Magneto

    NRG Power Purejet Time Flywheel magneto FLYWHEEL MAGNETO Code Action Duration 001058 Flywheel - Replacement 001067 Stator - Replacement 001173 Rotor - Replacement 001087 Flywheel cover - Replace- ment TIME - 14...

  • Page 219: Butterfly Valve

    NRG Power Purejet Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body 001171 Throttle body - Overhaul 004122 Air cleaner carburettor fitting - Replacement TIME - 15...

  • Page 220: Exhaust Pipe

    NRG Power Purejet Time Exhaust pipe UFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjust- ment TIME - 16...

  • Page 221: Air Cleaner

    NRG Power Purejet Time Air cleaner AIR PURIFIER Code Action Duration 001027 Body / air cleaner union - Re- placement 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning TIME - 17...
  • Page 222 NRG Power Purejet Time Frame HASSIS Code Action Duration 001053 Stand bolt - Replacement 004004 Stand - Replacement 004001 Frame - replace 004015 Footrest - Replacement 004171 Stand support plate - Re- placement 004143 Footrest support - replace TIME - 18...
  • Page 223 NRG Power Purejet Time Legshield spoiler RONT SHIELD Code Action Duration 004065 Front shield rear section - Re- placement 004064 Front shield - Replacement 003087 Wheel housing - Replace- ment 004167 Grill / radiator cover - Re- placement 004176 Air vent - Replacement...
  • Page 224 NRG Power Purejet Time Side fairings ENTRAL COVER Code Action Duration 004053 Spoiler - Replacement 004178 Footrest - Replacement 004011 Central chassis cover - Re- placement TIME - 20...

  • Page 225: Underseat Compartment

    NRG Power Purejet Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004059 Spark plug inspection flap - Replacement 004016 Helmet compartment - Re- placement 005046 Battery cover - change TIME - 21...
  • Page 226 NRG Power Purejet Time Plate holder ICENSE PLATE HOLDER Code Action Duration 005022 Rear turn indicators - Re- placement 005068 Rear turn indicator bulb - Re- placement 005005 Taillight - Replacement 005023 Rear tail light support - Re- placement 005091...
  • Page 227 NRG Power Purejet Time Mudguard UDGUARDS Code Action Duration 004009 Rear mudguard - Replace- ment 004052 Bumper - Replacement 004002 Front mudguard - Replace- ment TIME - 23...
  • Page 228 NRG Power Purejet Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004011 Central chassis cover - Re- placement 004072 Fuel filter - Replacement 004110 Fuel tank hose - Replace- ment...
  • Page 229 NRG Power Purejet Time Tank oil IL TANK Code Action Duration 004017 Oil reservoir - Replacement 005018 Oil reservoir float - Replace- ment 004095 Oil reservoir cock - Replace- ment 004091 Oil reservoir hose - Replace- ment TIME - 25...

  • Page 230: Rear Shock Absorber

    NRG Power Purejet Time Rear shock-absorber EAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorbers - Re- placement TIME - 26...
  • Page 231 NRG Power Purejet Time Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Re- placement 003073 Steering clearance - Adjust- ment 004119 Bearing / upper steering fifth wheel - Replacement TIME - 27...

  • Page 232: Handlebar Components

    NRG Power Purejet Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002060 Complete throttle control - Replacement 002059 Right hand grip - Replace- ment 005017 Stop switch - Replacement 003059 Counterweight - Replace- ment 002024 Front brake pump - replace...
  • Page 233 NRG Power Purejet Time Swing-arm WINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement TIME - 29...
  • Page 234 NRG Power Purejet Time Seat Code Action Duration 004003 Saddle - Replacement 004054 Seat lock hook - Replace- ment 002083 Saddle opening transmission - Replacement TIME - 30...

  • Page 235: Instrument Panel

    NRG Power Purejet Time Instrument panel NSTRUMENT UNIT AND HANDLEBAR COVER Code Action Duration 005014 Odometer - Replacement 004018 Handlebar front section - Re- placement 004019 Handlebar rear section - Re- placement 005078 Odometer glass - Replace- ment TIME - 31...

  • Page 236: Turn Signal Lights

    NRG Power Purejet Time Turn signal lights RONT LIGHT Code Action Duration 005067 Front turn indicator bulb - Re- placement 005008 Front headlamp bulbs - Re- placement 005002 Front headlamp - change 005012 Front turn indicator - Re- placement TIME - 32...

  • Page 237: Front Wheel

    NRG Power Purejet Time Front wheel RONT WHEEL Code Action Duration 002041 Front brake disc - Replace- ment 003040 Front wheel bearings - Re- placement 003037 Front wheel rim- Replace- ment 003047 Front tyre - Replacement 004123 Front wheel - Replacement...
  • Page 238 NRG Power Purejet Time In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel) Rear wheel EAR WHEEL Code Action Duration 001071 Rear wheel rim - replace 001016 Rear wheel - Replacement...

  • Page 239: Air Compressor

    NRG Power Purejet Time compressore aria AIR COMPRESSOR Code Action Duration 001168 Air compressor - Replace- ment 004160 Compressed air hose - Re- placement TIME - 35...

  • Page 240: Fuel Pump

    NRG Power Purejet Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replace- ment 004086 Petrol pump depression tube - Replacement 004072 Fuel filter - Replacement 004138 Fuel reverse pipe - Replace-...

  • Page 241: Electric Devices

    NRG Power Purejet Time Electric devices LECTRICS Code Action Duration 001023 Control unit - Replacement 001094 Spark plug cap - Replace- ment 005001 Electrical system - Replace- ment 005009 Voltage regulator - replace 005136 Resistance - Replacement 005044 Front lights cable unit- Re-...
  • Page 242 NRG Power Purejet Time ATTERY Code Action Duration 005007 Battery - Replacement 005024 Battery fuse - Replacement 005025 Fuse holder - Replacement 005011 Start-up remote control switch - Replacement TIME - 38...

  • Page 243: Electronic Controls

    NRG Power Purejet Time Electronic controls LECTRICAL COMMANDS Code Action Duration 005041 Starter button - Replacement 005040 Horn button - Replacement 005016 Key switch - Replacement 004096 Lock series - Replacement 004010 Antitheft lock - replace 005003 Horn - Replacement...
  • Page 244 NRG Power Purejet Time Transmissions PLITTER Code Action Duration 002012 Splitter - Replacement 002058 Mix / splitter transmission complete - Replacement 002057 Carburettor / splitter trans- mission complete - Replace- ment 002054 Throttle or splitter transmis- sion complete - Replacement...

  • Page 245: Brake Callipers

    NRG Power Purejet Time Brake callipers BRAKE CALLIPERS Code Action Duration 002007 Front brake pads - Replace- ment 002021 Front brake piping - Replace- ment 002039 Front brake calliper - Re- placement 002002 Rear brake pads - Replace- ment 002020...
  • Page 246 NRG Power Purejet Time Rear side fairings EAR COVERS Code Action Duration 004159 Plates / Stickers - Replace- ment 004056 Upper rear light cover - Re- placement 004036 Lower chassis cover - Re- placement 004085 Fairing (1) - Replacement 004129...

  • Page 247: Front Suspension

    NRG Power Purejet Time Front suspension Code Action Duration 003010 Front suspension - Service 003051 Complete fork - replace 003048 Fork oil seal - Replacement 003041 Fork stanchion - Replace- ment TIME - 43...

  • Page 248: Cooling System

    NRG Power Purejet Time Cooling system OOLING SYSTEM Code Action Duration 007001 Expansion tank - Replace- ment 007002 Water cooler - Replacement 001052 Coolant and air bleed - Re- placement 007024 Expansion tank cap - Re- placement 007013 Expansion tank / radiator...

Table of Contents