Table Of Contents - Derbi GPR125 Workshop Manual

Table of Contents

Table Of Contents2
Introduction4
Views Of The Machine6
Right Hand Side (Facing Forwards)6
Left Hand Side (Facing Forwards)6
Identification Of The Machine7
Frame Serial Number7
Manufacturer's Plate7
Engine Serial Number7
General Information8
Safety Regulations8
Maintenance Regulations8
Special Tools For The Engine8
Special Tools - Chassis16
Technical Data17
Tightening Torques26
Standard Bolts And Screws26
Engine Tightening Torques27
Chassis Tightening Torques29
Pdi (Pre-Delivery Inspection)30
Checking The Assembly And Preparing The Machine For Delivery To The First Purchaser (Pdi)31
Road Test Check32
Delivery To Customer32
Maintenance33
Location Of Elements33
Removing Bodywork Elements33
Pillion Passenger Seat37
Cowling Top Cover38
Cowling38
Bottom Tank Cover39
Bottom Fairing40
Cylinder Head Protective Cover40
Silencer End Cover41
Front Mudguard41
Top Tank Cover42
Cowling Side Closing Cover42
Front Bubble Screen43
Radiator Air Ducting43
Central Front Fairing44
Fuel Tank46
Rear Mudguard46
Bottom Cowling Closing Cover47
Rear Mudguard Supplement47
Periodical Maintenance Table48
Lubrication Points51
Inspection And Maintenance52
Adjusting The Timing Chain Play52
Transmission Chain53
Fitting A New Transmission Kit54
Inspecting The Exhaust System55
Inspecting The Ais Valve (Secondary Air)55
Air Filter Renewal56
Air Filter Box Drain Plug56
Inspecting The Spark Plug57
Adjusting The Clutch Lever58
Adjusting Idle Speed (Idle Speed)58
Adjusting The Throttle Cable59
Adjusting The Gear Lever60
Adjusting The Front Brake61
Adjusting The Rear Brake62
Inspecting The Front Brake Pads63
Renewing The Front Brake Pads63
Inspecting The Rear Brake Pads65
Renewing The Rear Brake Pads65
Inspecting The Tyres67
Inspecting The Coolant Level68
Recommended Coolant68
Changing The Engine Oil69
Recommended Engine Oil69
Quantity Of Engine Oil69
Inspecting The Engine Oil Level70
Recommended Oil For The Engine70
Adjusting The Valve Settings71
Adjusting Valve Settings That Are Outside That Specified73
Measuring The Compression Pressure79
Resetting Service Indicator80
Maintenance Pieces83
Identification Of Sets84
Removing The Engine From The Frame84
Dismantling The Engine84
Inspecting The Engine Elements84
Crankcase Location85
Crankcase Machined Diameter85
Balance Shaft – Gear Set85
Primary Shaft - Gear Set86
Distances Between Gears86
Half-Bearing87
Valve Guides88
Cylinder And Piston Sets88
Checking For Tight Valve Seating104
Steps To Follow To Dismantle The Valves104
Valve Grinding106
Valves, Valve Guides And Valve Springs109
Inspecting The Camshaft110
Timing Chain, Sprockets And Rollers111
Inspecting The Clutch Bell Housing115
Inspection Of The Forks And Gear Selector115
Inspecting The Oil Pump117
Inspecting The Oil Passages (Right Hand Side Casing Cover)118
Bearings And Retaining Rings118
Locking Rings And Washers118
Assembling The Engine119
Drive Shaft Spare Parts119
Crankshaft Parts121
Magneto Parts123
Gear Change Selector Parts126
Oil Pump Assembly Parts128
Clutch Bell Housing Parts133
Clutch Cover Parts136
Cylinder Head And Cylinder Parts138
Calculating The Bottom Gasket Thickness141
Valves And Camshaft Parts142
Thermostat Parts149
Fitting The Engine Into The Frame150
Fuel Supply System153
Dismantling The Carburettor153
Assembling The Carburettor153
Checking Level Of The Float Chamber164
Checking The Vacum Valve And Tapered Needle164
Checking The Automatic Choke166
Cooling System168
Diagram Of The System168
Description Of The System And Checking Of Elem168
Renewing The Water Pump Oil Seal168
Description Of The System And Checking Of Elements171
Checking The Elements172
Descripción Of The Lubrication System178
Descripcion Of The Lubrication System181
Chassis184
Inspecting The Wheels184
Front Wheel187
Fitting The Front Wheel188
Front Suspension189
Inspecting The Front Forks191
Fitting Front Suspension192
Inspecting The Steering Column195
Steering195
Dismantling The Semi-Handlebars196
Right-Hand Semi-Handlebar196
Left-Hand Semi-Handlebar196
Fitting The Semi-Handlebars197
Fitting The Semi-Handlebars Assembly197
Rear Wheel198
Fitting The Rear Wheel199
Inspecting The Rear Suspension200
Fitting The Rear Suspension201
Braking System202
Front Brake202
Rear Brake202
Dismantling Brake Calliper203
Fitting The Brake Calliper203
Removing The Front Wheel Cylinder204
Fitting The Front Brake Wheel Cylinder205
Checking The Brake Lever Master Cylinder206
Checking The Brake Calliper Main Cylinder206
Extracting The Front Brake Disk206
Fitting The Front Brake Disk207
Wear To The Front Brake Disk207
Front Brake Disk Distortion208
Bleeding The Brake System Pipe208
Dismantling The Brake Calliper211
Assembling Brake Calliper211
Dismantling The Rear Brake Cylinder212
Fitting The Rear Brake Wheel Cylinder213
Checking The Brake Lever Master Cylinder (Visual Check)214
Extracting The Rear Brake Disk214
Fitting The Rear Brake Disk215
Wear To The Rear Brake Disk215
Rear Brake Disk Distortion216
Electrical System220
General Indications220
Locating Electrical Components220
Wiring Diagram220
Checking Connectors221
Switch Connections Shown In This Manual222
Wiring Diagram - Gpr 125 4T224
Charging System225
Current Leakage225
Ignition System226
Description Of The System226
Description Of Components226
Starter Motor System227
Instrument Panel228
Adjusting The Time229
Resetting The Trip Meter Values229
Using The Chronometer229
Measuring The Time229
Connections231
Lighting And Indicating235
Adjusting The Headlight Beam (Right-Left)235
Changing The Headlight Bulbs235
Changing The Headlight235
Changing The Sidelight236
Dismantling236
Changing The Rear Light237
Changing The Turn Indicator Bulbs239
Changing The Horn239
Changing The Number Plate Light240
Fitting New Components241
Changing The Diode241
Changing The Regulator241
Changing The Cdi Unit242
Changing The Starter Relay242
Changing The Main Relay243
Changing The Instrument Panel243
Changing The Ht Coil244
Inspecting The Battery And Fuses245
Inspecting The Fuses246