Gilera Runner Purejet 2007 Workshop Manual
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Gilera Runner Purejet 2007 Workshop Manual

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WORKSHOP MANUAL
633499
Runner Purejet

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Summary of Contents for Gilera Runner Purejet 2007

  • Page 1 WORKSHOP MANUAL 633499 Runner Purejet...
  • Page 2 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 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. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual.
  • Page 4 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 5 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    Runner Purejet Characteristics Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...
  • Page 7 Runner Purejet Characteristics Dimensions and mass DIMENSIONS Specification Desc./Quantity Total vacuum weight gear se- 93 kg. quence Max width 720 mm. Max length 1800 mm. Wheelbase 1290 mm. Seat height 830 mm. Engine ENGINE Specification Desc./Quantity Type single-cylinder, two-stroke Number of cylinders Bore Stroke 39.3 mm...
  • Page 8 Runner Purejet Characteristics Electrical system ELECTRICS Specification Desc./Quantity Type of ignition Electronic ignition with H.V. coil controlled by the ECU Ignition advance (before the top dead centre) Variable integrated to the injection system Spark plug CHAMPION RG6YCA Battery 12V - 9Ah Fuse N°...
  • Page 9 Runner Purejet Characteristics Name Torque in Nm Ø Vite acc. 8,8 M5 Ferro, acciaio Ø Vite acc. 8,8 M6 su plastica con distanziali metallici Ø Vite acc. 8,8 M6 su ottone, rame, alluminio e loro leghe Ø Vite acc. 8,8 M6 Ferro, acciaio 10,5 Ø...

  • Page 10: Assembly Clearances

    Runner Purejet Characteristics GRUPPO MOTORE Name Torque in Nm Head tightening nut 10 ÷ 11 Vite spurgo liquido refrigerante 1 ÷ 2 Sensore temperatura 6 ÷ 8 Temperature sensor at the ECU 18 ÷ 22 Crankcase closure screw 12 ÷ 13 Transmission cover closing screw 12 ÷...
  • Page 11 Runner Purejet Characteristics Name Initials Cylinder Piston Play on fitting Pistone 2° maggiora- 40,411-40,418 40,357-40,364 0,047-0,061 zione Pistone 2° maggiora- 40,418-40,425 40,364-40,371 0,047-0,061 zione Piston rings ANELLI DI TENUTA Name Description Dimensions Initials Quantity Anello di tenuta 0,10 ÷ 0,25 Anello di tenuta 1°...
  • Page 12 Runner Purejet Characteristics AXIAL PLAY CONNECTING ROD - CRANKSHAFT Name Description Dimensions Initials Quantity Connecting rod 11.75 0 -0.05 0.25 ÷ 0.50 Shoulder washer 0.5 ±0.03 0.25 ÷ 0.50 Semi-shaft, trans. side 13.75 +0.04 0 0.25 ÷ 0.50 Semi-shaft, flywheel 13.75 +0.04 0 0.25 ÷...
  • Page 13 Runner Purejet Characteristics Slot packing system Montare il cilindro senza installare la guarnizione alla base. Applicare un comparatore centesimale sull'attrez- zo e azzerarlo su un piano rettificato. Montare l'attrezzo sulla sommità del cilindro fis- sandolo con due dadi ai prigionieri, rispettando la coppia di serraggio e portare il pistone al P.M.S.
  • Page 14 Runner Purejet Characteristics Product Description Specifications AGIP PERMANENT PLUS Coolant Monoethylene glycol antifreeze fluid, CU- NA NC 956-16 AGIP GREASE SM 2 Greasing the driven pulley bushing Soap-based lithium grease with NLGI 2 Molybdenum Disulphide; ISO-L- XBCHB2, DIN KF2K-20 CHAR - 14...
  • Page 15 INDEX OF TOPICS TOOL OOLING...
  • Page 16 Runner 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 bearings 001467Y009 Driver for OD 42-mm bearings 001467Y013 Pliers to extract ø...
  • Page 17 Runner Purejet Tooling Stores code Description 001467Y017 Bell for bearings, OD 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 001467Y029 Bell for bearings, O.D. 38 mm 002465Y Pliers for circlips 004499Y Camshaft bearing extractor 004499Y007 Half rings 006029Y Punch for fitting fifth wheel seat on steer- ing tube TOOL - 17...
  • Page 18 Runner Purejet Tooling Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020080Y Punch for removing 12-mm bearings 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor TOOL - 18...
  • Page 19 Runner Purejet Tooling Stores code Description 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020166Y Pin lock fitting tool 020168Y Water seal punch mount on half-crank- case 020169Y Water pump crankshaft fitting and remov- al spanner 020170Y Water pump/mixer command gear ex- tractor TOOL - 19...
  • Page 20 Runner Purejet Tooling Stores code Description 020171Y Punch for driven pulley roller bearing 020209Y Spring hook 020265Y Bearing fitting base 020272Y Piston position check tool 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump TOOL - 20...
  • Page 21 Runner Purejet Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger TOOL - 21...
  • Page 22 Runner Purejet Tooling Stores code Description 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 020362Y 12-mm guide 020363Y 20 mm guide TOOL - 22...
  • Page 23 Runner Purejet Tooling Stores code Description 020409Y Multimeter adaptor - Peak voltage detec- tion 020376Y Adaptor handle 020412Y 15 mm guide 020439Y 17 mm guide 020444Y Test probe removal / fitting tool 020456Y Ø 24 mm adaptor TOOL - 23...
  • Page 24 Runner Purejet Tooling Stores code Description 020451Y Starting ring gear lock 020452Y Tube for removing and refitting the driven pulley shaft 020460Y Scooter diagnosis and tester 020481Y Control unit interface wiring 020565Y Flywheel lock calliper spanner 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 24...
  • Page 25 Runner Purejet Tooling Stores code Description 020614Y Diagnostic tester programming software 020615Y Carbon dam ring fitting kit 020616Y Fuel pressure control kit 020617Y Air pressure check kit 020620Y Water pump impeller stop 020621Y HV cable extraction adaptor TOOL - 25...
  • Page 26 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 27: Maintenance Chart

    Runner Purejet Maintenance Purejet engines use a very lean air-petrol mixture when running at idle, with its effective percentage varying as a function of the engine temperature and power absorption. The throttle body supplies large amounts of air and the idle speed is kept at 2,000 rpm by adequately leaning down the mixture through the adjustment of the fuel injection timing.
  • Page 28 Runner Purejet Maintenance Action Transmission elements - lubrication Safety locks - check Suspensions - check Electrics - Check Headlight - adjustment check Tyre pressure and wear - check Vehicle and brake test - road test AT 15,000 KM , 45,000 KM Action Hub oil level - Check / Replace Spark plug - replacement...

  • Page 29: Spark Plug

    Runner Purejet Maintenance Action Suspensions - check Electrics - Check Headlight - adjustment check Tyre pressure and wear - check Vehicle and brake test - road test AT 60,000 KM Action Hub oil level - Check / Replace Spark plug - replacement Fuel filter - replacement Air filter - clean Transmission gas mixer- adjust...
  • Page 30 Runner Purejet Maintenance - Disconnect the lug of the spark plug and remove - Examine it carefully and if the insulation coating is splintered or damaged, replace it. - Measure the distance between the electrodes using a feeler gauge and if necessary regulate it by carefully bending the external electrode.

  • Page 31: Air Filter

    Runner Purejet Maintenance Air filter Removal - Remove the 6 screws shown in the picture. Cleaning - Wash with soap and water. - Dry. - Impregnate with fuel mixture of 50% fuel and oil. CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

  • Page 32: Fuel Filter

    Runner Purejet Maintenance Fuel filter To access the fuel filter remove the • left side. • Remove the filter from its support • Disconnect the tube from the fuel tank taking care to arrange a bowl to collect the fuel present in the tank. Please note the tank is not fitted with a tap.
  • Page 33 Runner Purejet Maintenance Grease the ends of the cable. Transmission adjustment Set the command cables: Mix cable: see the following procedure "Mixer Timing". Gas cable: adjust so there is no play in the sheathes. Splitter command cable: adjust so there is no play in the gas knob. All transmissions must be regulated so there is no play in the sheathes.
  • Page 34 Runner Purejet Maintenance Cooling system Level check - Remove the front grille - Check that the coolant level is between the min and max reference marks. Top up with recommended coolant, if necessary. Recommended products AGIP PERMANENT PLUS Coolant Monoethylene glycol antifreeze fluid, CUNA NC 956-16 See also Legshield...
  • Page 35 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 36: Engine Overheating

    Runner Purejet Troubleshooting Engine Engine overheating ENGINE OVERHEATING Possible Cause Operation No coolant in the cooling circuit Restore the level Incorrect air bleeding Repeat the operation Thermostat remains closed Replace Fluid leak in the radiator Replace the radiator Loss of fluid from the system Servicing the system Coolant leaks from crankcase draining hole Replace coolant sealing ring on half-crankcase from transmis-...
  • Page 37 Runner Purejet Troubleshooting Possible Cause Operation Brake disc slack or distorted Check the locking of the brake disc screws; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump breakdown, replace Brakes overheating OVERHEATING BRAKES...
  • Page 38 Runner Purejet Troubleshooting Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightness of the upper ring-nut. If irregularities con- tinue to appear in rotating the steering even after making the adjustments, check the housings where the ball bearings ro- tate: replace if not fitted.
  • Page 39 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 40 Runner Purejet Electrical system ELECRTRICS Specification Desc./Quantity Instrument panel Headlight assembly Stop switch on front brake Plug with contacts Starter button Right front turn indicator Key switch Fuel level sender Voltage regulator Coil Spark plug Fuel injector Air injector Water temperature sensor Throttle body pos.
  • Page 41 Runner Purejet Electrical system Specification Desc./Quantity Lampada per lampeggiatori Stop light bulb Direction indicator bulb Oil mix warning light com. Start-up relay Electronic control unit Resistance 27Ω Fuel pump Horn 7,5A fuse Turn indicator switch Left front turn indicator Horn button Commutatore lampeggiatori Light switch Rear stop light switch...
  • Page 42 Runner Purejet Electrical system Headlights and automatic starter section HEADLIGHTS AND TURN INDICATORS Specification Desc./Quantity Voltage regulator Flywheel magneto Turn indicator device com. 2 turn indicator warning light bulbs 12V-2w 4 turn indicator lamps 12V-10w Turn indicator switch Plug with contacts Parking light bulb 12V-5W Rear positioning bulbs...
  • Page 43 Runner Purejet Electrical system Battery recharge and starting RECHARGING BATTERY AND START SECTION Specification Desc./Quantity Voltage regulator Flywheel magneto 7,5A fuse 15A fuse Starter remote control Starter motor Starter button Brake light filament 12V-21W Front brake stop button Rear stop light switch Battery 12V - 9Ah Fuse...
  • Page 44 Runner Purejet Electrical system Level indicators and enable signals section LEVEL INDICATORS AND HORN SCHEME Specification Desc./Quantity Water temperature sensor Resistance 27Ω 0,5W Water temperature gauge 7,5A fuse Key switch contacts Fuse Battery 12V - 9Ah Horn button Claxon in c.c. Fuel resreve light Fuel indicator Fuel level sending unit...
  • Page 45 Runner Purejet Electrical system Instruments and warning lights control board CONTROL PANEL FOR INSTRUMENTS AND WARNING LIGHTS Specification Desc./Quantity Ground lead Plug with contacts Left turn indicator High beam switch Mixer oil warning light control Fuel level sending unit Fuel level transmitter Turn indicator device com.
  • Page 46 Runner Purejet Electrical system not have a connection to the key switch. The three phase generator provides a significant recharge power and at low rpm, a good compromise is obtained between distributed power and idle stability. Stator check Disconnect the connector from the voltage regu- lator and check for continuity between each yellow wire with the other two.
  • Page 47 Runner 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. Start the engine and measure the current distrib- uted by the circuit with the lights on and engine at high rpm.
  • Page 48 Runner 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 49 Runner Purejet Electrical system STARTER MOTOR Specification Desc./Quantity Starter motor Voltmeter Starter motor contactor Start button Battery 12V-9Ah Ammeter See also Centre-stand Side fairings Turn signals system check The turn indicator circuit is managed by an inter- mittent device. If there are any problems with this circuit check: - The 7,5A fuse indicated in the photograph after removing the front cowling.
  • Page 50 Runner Purejet Electrical system indicator switch for the right bulbs and to the PINK cable for the left bulbs. See also Legshield level indicators Composed of fuel level transmitter, analogical reading instrument and fuel reserve light. If problems occur check: - The fuel reserve light - The 7,5A fuse in the photograph after having re- moved the front casing...
  • Page 51 Runner Purejet Electrical system Legshield Rear rack Lights list The lighting system turns on when the key is turned to ON. It is possible to select the high beams using the light switch. If there are problems with the lighting system c h e c k : - Bulb efficiency - The 7,5A fuse shown in the picture removing the...
  • Page 52 Runner Purejet Electrical system should be about 1.27, corresponding to 31° Bé, and the values have stabilised. The duration of the charging operations must be 15 - 20 hours. 4) Once the charging is complete, level out the acid (add distilled water or remove excess acid), put on the caps and clean carefully.
  • Page 53 Runner Purejet Electrical system When charging is completed, check the level and density of the electrolyte as well as the voltage of each element. If the vehicle is not used for long periods of time (1 month or longer) the battery must be periodically recharged.
  • Page 54 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 55 Runner Purejet Engine from vehicle Removal of the engine from the vehicle - Remove the side panels - Remove the muffler Remove the rear brake line clamps on the trans- mission cover as shown in the figure - Loosen the 5 rear wheel clamping screws to re- move the brake calliper - Remove the brake calliper using the 2 screws shown in the figure.
  • Page 56 Runner Purejet Engine from vehicle - Remove the generator cable connector Remove the fuel connectors from the fuel injector, as follows: - Press the union pipe downwards - Hold the pipe downwards and pull the safety ring upwards - Extract the connector from the fuel injector If the connector is difficult to extract, do not force it too much and combine the rotation movement with pushing-pulling stresses.
  • Page 57 Runner Purejet Engine from vehicle - Remove the screw fixing the fuel piping clamp to the engine on the flywheel side - Remove the electric connectors from the fuel and air injector - Remove the electric connector from the throttle body - Remove the plastic clamp connecting the electric cable of the throttle body to the air pipe shown in...
  • Page 58 Runner Purejet Engine from vehicle - Remove the belt cooling cover - Release the mixer control cable using the special hole as shown - Remove the starter wiring from the relay and from the grounding wire - Remove the plastic clamp connecting the starter wiring to the swinging arm - Remove the screw fixing the fuel piping clamp to the engine on the transmission side...
  • Page 59 Runner Purejet Engine from vehicle - Remove the coolant temperature sensor con- nector - Remove the cooling system piping from the en- gine and discharge the fluid - Remove the air filter sucking sleeve - Remove the lower suspension fixing - Use two 17 mm Allen wrenches to remove the engine/swinging arm fixing pin - Remove the oil mixer pipe from the tank...
  • Page 60 Runner Purejet Engine from vehicle - To refit, perform the operations in the reverse di- rection and ensure that the electric wiring is prop- erly fixed to components such as: air injector, fuel injector, throttle body, generator, coolant temper- ature sensor. - Carefully clean the connectors removing any dirt and foreign material - Respect the clamps of the fuel lines to the engine.
  • Page 61 INDEX OF TOPICS NGINE...

  • Page 62: Automatic Transmission

    Runner 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 63: Removing The Driven Pulley

    Runner Purejet Engine Removing the driven pulley - Lock the clutch bell housing with the specific tool. - Remove the nut, the clutch bell housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE PULLEY MOUNTED.
  • Page 64 Runner Purejet Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch Inspecting the clutch - Check the thickness of the clutch mass friction material.
  • Page 65 Runner Purejet Engine - 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. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 66 Runner Purejet Engine Stationary driven half-pulley/Standard diame- Ø 33.965 to 33.985 mm Stationary driven half-pulley / Minimum diam- eter admitted after use Ø 33.96 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.
  • Page 67 Runner Purejet Engine Refitting the driven half-pulley bearing - Fit a new ball bearing with the specific tool. - Fit the ball bearing retention snap ring. - Fit the new roller bearing with the wording visible from the outside. CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.
  • Page 68 Runner 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 - Measure the free length of the spring Characteristic Standard length 118 mm...

  • Page 69: Removing The Driving Pulley

    Runner Purejet Engine 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 ÷ 44 N·m Drive-belt - Make sure the driving belt is not damaged and does not have cracks in the toothed grooves.
  • Page 70 Runner 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 71 Runner Purejet Engine Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting. N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.
  • Page 72 Runner Purejet Engine See also Refitting the clutch Removing the wheel axle - Remove the intermediate gear and the complete gear wheel axle. - When removing the intermediate gear pay atten- tion to the various shim adjustments. Removing the wheel axle bearings - Remove the oil seal and the seeger ring.
  • Page 73 Runner Purejet Engine - Position the special tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the figure. Expel the driven pulley shaft with the aid of a press. Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Inspecting the hub shaft - Check that the three shafts exhibit no wear or...
  • Page 74 Runner Purejet Engine 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40-mm adaptor Refitting the wheel axle bearing - Heat the half crankcase on the transmission side using a thermal gun. - After lubricating its outer strip, insert the bearing with the special adapter with the aid of a hammer.

  • Page 75: Removing The Stator

    Runner Purejet Engine Flywheel cover Removing the stator - Remove the flywheel cover. • Use a specific compass wrench and a 15 mm Allen wrench to remove the flywheel lock-nut. Specific tooling 020565Y Flywheel lock calliper spanner • Use a specific extractor to remove the flywheel Specific tooling 020162Y Flywheel extractor •...
  • Page 76 Runner Purejet Engine • Remove the coolant inlet duct • Remove the two stator fixing screws • Remove the stator with wiring and revolution sensor Locking torques (N*m) Flywheel nut 40 to 44 N.m Refitting the stator - To refit, perform the removal procedures in the reverse direction. Refitting the flywheel cover •...

  • Page 77: Removing The Cylinder Head

    Runner Purejet Engine • Keeping the flywheel connector rubber clamp on the coolant inlet hose, refit the flywheel cover paying attention in inserting the strap in the groove. • Tighten the 4 studs, noting that the two longer golden screws are inserted in the 2 top holes and are also responsi- ble for restraining the secondary air- box.
  • Page 78 Runner Purejet Engine • Remove the injection head, including the fuel in- jector and the pressure regulator, using the 2 screws shown in the figure • Remove the spark plug • Remove the temperature sensor shown in the figure To remove the air injector, extract the dust cover and use a screwdriver to remove the injector as shown in the figure N.B.
  • Page 79 Runner 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 80: Inspecting The Small End

    Runner Purejet Engine • Remove the 2 plug stops by a screwdriver inser- ted into the special slits on the piston • Remove piston pin and remove the piston N.B. USE PAPER OR A CLOTH TO CLOSE THE CYLINDER HOUSING MOUTH ON THE CRANKCASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE.

  • Page 81: Inspecting The Piston

    Runner Purejet Engine Inspecting the wrist pin - Check the wrist pin external diameter using a mi- crometer Characteristic Wrist pin: standard diameter 12 +0.005 +0.001 mm Inspecting the piston - Measure the bearings on the piston using a bore meter - Calculate the piston-pin coupling clearance.

  • Page 82: Removing The Piston

    Runner Purejet Engine Inspecting the cylinder • Check that the cylinder exhibits no seizure. If it does, replace or adjust it, while respecting the al- lowable oversizes. • Use a bore meter to measure the cylinder inside diameter according to the directions shown in the figure.
  • Page 83 Runner Purejet Engine • Fit piston and wrist pin on the connecting rod, with piston facing the outlet • Insert the wrist pin stop ring in the specific tool with the aperture in the position shown on the tool, as in the figure •...
  • Page 84 Runner Purejet Engine Choosing the gasket • Temporarily fit the cylinder on the piston, without the basic gasket. • Fit a dial gauge on the specific tool, using the short union as shown in the figure. Use a reference plane to reset the dial gauge with a pre-load of a few millimetres.
  • Page 85 Runner 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 • Screw the 4 head fixing nuts and tighten them in crossed sequence to the prescribed torque Locking torques (N*m) Head fixing nuts:...
  • Page 86 Runner Purejet Engine • Refit the dust cover onto the air injector. N.B. NOTE THAN WHEN THE AIR INJECTOR IS REFITTED, THE CARBON DAM O-RING MUST BE NEW. IF A NEW AIR IN- JECTOR IS FITTED, THE NEW CARBON DAM RING IS ALREADY PRESENT.
  • Page 87 Runner 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 88 Runner 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 Cylinder assy. and timing system Removing the driving pulley Removal Removing the driven pulley Splitting the crankcase halves...
  • Page 89 Runner 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. Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an...
  • Page 90 Runner 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 bearings Refitting the crankshaft bearings - This operation requires assembly by temperature - Dip the bearings in oil bath when this is still cold.
  • Page 91 Runner Purejet Engine 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 92 Runner Purejet Engine - 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. Avoid any method that may impair the crankcase fitting surfaces. - To facilitate this operation, remove the rotor.
  • Page 93 Runner Purejet Engine - Let the crankcase half temperature settle with the crankshaft temperature. - Install the specific crankcase separation plate again without installing the crankshaft guard. - Keep the central thrust screw loosened during assembly. - Move the 4 fixing screws to the end of stroke and loosen them again by the same angle (e.g.
  • Page 94 Runner Purejet Engine - Insert 5 more screws and tighten at the prescribed torque. Locking torques (N*m) Crankcase closing screws: 12 -13 Nm 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.
  • Page 95 Runner Purejet Engine Limit value with cold crankcase 0.02 ÷ 0.03 mm 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 96 Runner 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 97 Runner Purejet Engine - Remove the flywheel cover. - Turn the crankshaft to check that the eccentric track exhibits no unusual wear or signs of over- heating. Refitting Air compressor refitting - Place the shaft with the eccentric at its lower dead point.
  • Page 98 Runner Purejet Engine - Refit the throttle body manifold. - Refit the flywheel cover. Lubrication 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.
  • Page 99 Runner Purejet Engine - Lubricate bearings and connecting rod head us- ing 2T oil. - Refit the thermal unit - Refit the compressor - Refit the throttle body - Refit the flywheel - stator - Refit the mixer - Refit the driven pulley - Refit the driving pulley Oil pump Removal...
  • Page 100 Runner Purejet Engine - Remove the pipe from the oil inlet union in the pump case See also Removing the driving pulley Removing the driving pulley Refitting - To refit, perform the removal procedures in the reverse direction. - Perform purging after refitting, using the screw shown in the figure.
  • Page 101 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 102: Removing The Front Wheel

    Runner Purejet Suspensions 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. Front wheel hub overhaul - Remove the front wheel - Keep the wheel level by means of two wooden wedges - With the appropriate pliers and tool remove the...
  • Page 103 Runner Purejet Suspensions - Check that the bearings do not show flaws or jamming. If there is, replace it. - Check that the internal spacer does not show ab- normal wear. If there is, replace it. - With a hot air gun heat the seat of the bearing on the brake calliper side - With an appropriate tool remove the bearing on the brake disk side...

  • Page 104: Front Fork

    Runner Purejet Suspensions Removal - Remove the front handlebar cover. - Remove the rear handlebar cover. - After removing the transmissions and discon- necting the electrical terminals, remove the bolt «A» and the handlebar - Check all components and replace faulty parts. N.B.
  • Page 105 Runner Purejet Suspensions Removal - Remove the front brake calliper. - Remove the odometer cable from the reduction gear box. - Remove the front mudguard. - Remove the handlebar. After removing the steering ring-nut using the spe- cial tool, lean the vehicle on one side and extract the steering tube.
  • Page 106 Runner Purejet Suspensions - 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 QUANTITY OF GREASE (AROUND 3 GR.) Recommended products AGIP GREASE MU3 Grease for odometer...

  • Page 107: Steering Column

    Runner Purejet Suspensions Refitting Lubricate the seats and the balls with the grease recommended. - Lock at the prescribed torque and turn the key anticlockwise by 90° to 100°. Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect...
  • Page 108 Runner Purejet Suspensions - Using the special tool, refit the upper and lower bearing seats on the headstock. Specific tooling 001330Y Tool for fitting steering seats Steering bearing Removal Bearing housing on the fork overhaul Check the condition of the fifth wheel and the fifth wheel seat on the fork (steering tube).
  • Page 109 Runner Purejet Suspensions - Remove the handlebar. - Remove the cover of the steering collar shown in the figure - Remove the collar of the steering bearing using the specific tool Specific tooling 020055Y Wrench for steering tube ring nut See also Front handlebar cover Rear handlebar cover...

  • Page 110: Removing The Rear Wheel

    Runner Purejet Suspensions Removing the rear wheel - Remove the wheel loosening the five clamps. Refitting the rear wheel - On refitting, tighten to the prescribed torque in a cross over pattern. Locking torques (N*m) Rear wheel: 20 - 25 Nm Shock absorbers Removal To replace the shock absorber you just need to...
  • Page 111 Runner Purejet Suspensions Refitting When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at the prescribed torque. Locking torques (N*m) Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m Centre-stand Expulsion of kickstand bracket fastening pin - Remove the stand support bracket from the en-...
  • Page 112 INDEX OF TOPICS INJ PJ PURE JET INJECTION...
  • Page 113 Runner 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 114 Runner Purejet pure jet injection • Fuel consumption reduction • Lubricant consumption reduction • Discharge emission reduction. Emissions are further limited by the catalyser. The injection system achieves these results by: • Air washing of the 2T cycle • Stratified load •...

  • Page 115: Troubleshooting

    Runner Purejet pure jet injection 8. Do not invert the polarity when fitting the battery. 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 116 Runner Purejet pure jet injection Dirty fuel filter 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 117 Runner Purejet pure jet injection AUTO-DIAGNOSTIC Specification Desc./Quantity PRIORITY 1 Flashing injection indicator. This signal identifies abnormalities that could cause serious damage to the engine or stopping of the vehicle if the vehicle continues to be used. PRIORITY 2 Steady injection indicator. This denotes faults that impair the vehicle use since the engine can stop or remain idle.
  • Page 118 Runner Purejet pure jet injection • ECU INFORMATION To access the individual functions, the tester must be connected to the vehicle diagnostic outlet and the ECU must be on. • To connect the scooter diagnostic tester, raise the seat • Remove the battery cover •...
  • Page 119 Runner Purejet pure jet injection PARAMETERS Specification Desc./Quantity ENGINE RPM Displays the regime of the engine in all conditions, including the start-up ENGINE TEMP. °C Indicates the coolant temperature THROTTLE OPEN. % Indicates the % of opening of the throttle valve T.
  • Page 120 Runner Purejet pure jet injection Specification Desc./Quantity Light off G21 P1125 TPS1 TPS1 signal missing. Voltages close to 0V (short circuit) Voltages close to 5V (open circuit) Light on G22 P1127 TPS2 OFFSET TPS2 signal is not as expected. Light off G22 P1128 TPS2 TPS2 signal missing Voltage close to 0V (short circuit)
  • Page 121 Runner Purejet pure jet injection Specification Desc./Quantity Light on Faults are reported by a dark dot on one of the reference columns. The recognition occurs in 3 modes: - Dot on the column marked «A». The fault is «CURRENT» and present during the check - Dot on the column marked with «O».
  • Page 122 Runner Purejet pure jet injection ACTIVE DIAGNOSTICS Specification Desc./Quantity AIR INJECTOR Wait for the sound confirming 5 openings FUEL INJECTOR Wait for the sound confirming 5 openings HV COIL Wait for the sound confirming 5 coil magnetic activity (weak signal) FUEL PUMP Wait for the sound confirming the pump rotation for approx.
  • Page 123 Runner Purejet pure jet injection component layout POSITION OF COMPONENTS Specification Desc./Quantity Temperature sensor "WARNING" light HV coil N° 2 15 A fuses Diagnostic socket EMS electronic injection control unit Throttle body Coolant temperature sensor Fuel injector fuel pump INJ PJ - 123...
  • Page 124 Runner Purejet pure jet injection Specification Desc./Quantity Flywheel - rpm timing sensor terminal layout on cpu 1 - Ground 3 - Fuel injector (negative) 4 - To diagnostic indicator (negative) 5 - Coolant temperature indicator (button negative) 7 - TPS 1 signal 9 - Coolant temperature sensor (positive) 10 - TPS 2 signal 12- H.V.
  • Page 125 Runner Purejet pure jet injection 19 - Phase rpm sensor positive 20 - Phase rpm sensor negative 21 - Serial line for diagnostic tester EMS system diagram SYSTEM DIAGRAM Specification Desc./Quantity Voltage regulator Flywheel magneto pick - up Fuel injector Water temperature sensor Throttle body pos.
  • Page 126 Runner Purejet pure jet injection cpu power circuit INJECTION ECU POWER SUPPLY CIRCUIT Specification Desc./Quantity Injection warning light 7.5A Key switch Fuel pump Air injector Fuel injector HV coil Voltage regulator Battery 12V - 9Ah Fuse To services To flywheel magneto 1-Turn the key switch to the «ON»...
  • Page 127 Runner Purejet pure jet injection 4- The ignition light does not switch on and the pump is correctly activated. Perform all the checks required in the injection light section. 5- Connect the diagnostic tester of scooter. Select the «errors» function and check the faults that are signalled in current status.
  • Page 128 Runner Purejet pure jet injection 16- The ECU supplies are conform. 17- Check all electrical installation connections for any possible problems that are related to loosening or oxidation. GO TO point 20 18- Check the main supply. GO TO point 20 19- Check the power supply to panel.
  • Page 129 Runner Purejet pure jet injection 25- The supply is conform. 26- Check the efficiency of the 15A fuse and of the connections to the fuse-holder (red - blue) YES point 27 NO point 28 27- Restore the continuity of the line connecting fuse with pin 15 (blue cable) GO TO point 24 28- If connections are conform and the fuse is...
  • Page 130 Runner Purejet pure jet injection - Voltage adjuster GO TO point 24 34- After confirmation of the correct main supply (point B) check the power supply to panel. Check the following conditions: 1 - 17 = battery voltage (switch on «ON») 1 - 17 = 0V (switch on «OFF») YES point 35 NO point 36 35- The ECU power supply to panel is conform.
  • Page 131 Runner Purejet pure jet injection YES point 45 NO point 44 44- IlThe fuse is again burnt. Check the wiring more accurately and, if necessary, replace the ECU GO TO point 34 45- Make a good visual check of the wiring to avoid possible causes for short circuits. Reconnect the 7.5 A fuses.
  • Page 132 Runner Purejet pure jet injection 1. Check that the insertion of the connection to the vehicle is correct. YES point 3 NO point 2 2. Restore the connection. 3. Turn to «OFF», wait a few seconds and turn again to «ON». If the fault persists, make the fol- lowing checks: GO TO point 4 4.
  • Page 133 Runner Purejet pure jet injection 10. Restore the wiring connection. 11. The diagnostic tester connection meets specs. If the problem persists, check the diagnostic tester and the ECU, if necessary. 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 134 Runner Purejet pure jet injection 3 Fuses 7.5A 4 Key switch 5 Fuel pump 6 Fuses 15A 7 Battery 12V 9Ah A Ai services B + Fixed The injection indicator should turn on every time you switch to "ON" while the engine is started. When the self-diagnosis detects a fault, it commands the lightingof the indicator according to the priority level: •...
  • Page 135 Runner Purejet pure jet injection 020481Y Control unit interface wiring 5. Remove the 7.5A 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.
  • Page 136 Runner 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. See also autodiagnosis throttle position sensor circuit (T.P.S.)
  • Page 137 Runner Purejet pure jet injection COMPONENTS LAYOUT 1 ECU 2 TPS (Throttle Position Sensor) 3 Coolant temperature sensor A + 12V under panel B + 12V fixed The gas valve position sensor (TPS) is an integral part of the throttle body, and therefore it cannot be removed.
  • Page 138 Runner Purejet pure jet injection For the check, proceed as follows. Connect the diagnostic tester to the vehicle. Select the «parameters» function. The following values are reported: THROTTLE OPEN. % The displayed value refers to the valve opening percentage. Check that a progressive actuation of the valve corresponds to an equal increase of the opening percentage value.
  • Page 139 Runner Purejet pure jet injection 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. Acknowledge- Free TPS2 ment occurs when the signal voltage is close to: 0V = short circuit 5V = open circuit...
  • Page 140 Runner Purejet pure jet injection N° 1 (TPS) - 16 (ECU) = Ohm Continuity N° 2 (TPS) - 7 (ECU) = Ohm Continuity N° 3 (TPS) - 10 (ECU) = Ohm Continuity N° 4 (TPS) - 18 (ECU) = Ohm Continuity YES point 4 NO point 3 3.
  • Page 141 Runner Purejet pure jet injection 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. 16(-) - 18 (+) = 5 V YES point 14 NO point 13 13.
  • Page 142 Runner Purejet pure jet injection See also menù diagnosis tester T.P.S. signal reset The throttle body is supplied with gas valve and is precalibrated. Precalibration entails regulating the minimum opening of the gas valve to obtain a certain flow of air under preset reference conditions. Pre-calibration results in an optimum air capacity for the engine management during start up or during idle running, and at any possible temperature during the use of the vehicle.
  • Page 143 Runner Purejet pure jet injection 1- Connect the scooter diagnostic tester Select the «parameters» function and visualise the indicator showing the «TPS to reset» GO TO point 2 GO TO point 4 2. The diagnostic tester responds YES. Continue to make the following checks: - The throttle body is not tampered with - The control transmission is correctly registered - The connector of the throttle body is correctly connected...
  • Page 144 Runner Purejet pure jet injection Select «RESET TPS» from the menu. By using this procedure, the following indications are visualised. GO TO point 2 2. Check for possible errors Wait GO TO point 3 GO TO point 4 3. Errors present Cancel all errors Press a key GO TO point 5...
  • Page 145 Runner Purejet pure jet injection 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. rpm-timing sensor circuit TERMINALS: 19 - 20 CONDITIONS: Engine driven by the starter (500-600 RPM)
  • Page 146 Runner Purejet pure jet injection • Fuel injector • Air injector • H.V. coil Every actuator is controlled with a specific timing. Control is made possible by the phase - rpm signal, coming from a phonic wheel obtained on the outer diameter of the flywheel magneto rotor. The flywheel is divided into 24 sectors and is provided with 23 teeth controlling the gap variations to the pick - up core.
  • Page 147 Runner Purejet pure jet injection Specific tooling 020481Y Control unit interface wiring 5. Check the continuity of the connection lines of the sensor from the ECU to the flywheel connector 19 - red lead= Ohm continuity 20 - brown lead= Ohm continuity YES point 7 NO point 6 6.
  • Page 148 Runner 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. GO TO point 9 11.
  • Page 149 Runner Purejet pure jet injection 14. Restore or replace the stator with phase - rpm sensor. GO TO point 17 15. Check the phase - rpm sensor resistance 19 - 20 = Ohm…… at 20° (detected 106.7W) YES point 17 NO point 16 N.B.
  • Page 150 Runner Purejet pure jet injection H.T. coil circuit TERMINALS: 1 - 12 CONDITIONS: Engine stopped, switch in any position STANDARD VALUES: Battery voltage COMPONENTS LAYOUT 1 ECU 2 15A fuses 3 Air injector 4 Fuel injector 5 H.V. coil 6 Key switch 7 12V 9Ah Battery A + under panel B Al magnet flywheel...
  • Page 151 Runner Purejet pure jet injection The core dwelling time is optimised in function of the power required to the HV coil. Of course, longer dwelling times are used during start up. The ECU self-diagnosis also checks the coil power supply circuit, detecting interruptions or short cir- cuits.
  • Page 152 Runner Purejet pure jet injection 4. Error on the H. V. coil in «occurred» or stored status. Continue with circuit checks. Possible problems: - 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.
  • Page 153 Runner 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 154 Runner 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 155 Runner 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 156 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light to check timing 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 157 Runner 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. YES point 16 NO point 8 6- Engine rpm are as expected and pressure is lower than specifications.
  • Page 158 Runner 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 159 Runner Purejet pure jet injection COMPONENTS LAYOUT: 1 ECU 2 Fuses 15A 3 Air injector 4 Fuel injector 5 H.V. coil 6 Voltage regulator 7 12V - 9Ah battery A + under panel B To the magnet flywheel The air injector is the main component of the electro-pneumatic injection. For convenience, the injector called air injector even though it actually injects an air and fuel mixture.
  • Page 160 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 2- Enable the air injector diagnostic. Check the 5 sounds that denote the air injector activation. Check the tester response. YES point 3 NO point 4 NO point 5 3- The air injector has enabled 5 times and the tester has returned "test finished successfully".
  • Page 161 Runner Purejet pure jet injection 12- Check the efficiency of fuse 20A and restore the wiring if required. GO TO point 11 13- Check the continuity of the air injector control line. 13 - pink (injector connector) = continuity YES point 15 NO point 14 N.B.
  • Page 162 Runner Purejet pure jet injection 20- If very different resistive values are detected, replace the air injector. GO TO point 19 21- Check the air injector winding negative insu- lation. 1 - any pin of the injector> or = 1MOhm YES point 23 NO point 22 22- Replace the air injector.
  • Page 163 Runner Purejet pure jet injection fuel pump circuit TERMINALS: 1 - 14 CONDITIONS: Switch in «ON» position after the engine timing STANDARD VALUES: less than 0.1 V TERMINALS: 1 - 14 CONDITIONS: Switch in «ON» position after timing with engine still STANDARD VALUES: Battery voltage COMPONENTS LAYOUT: 1 ECU...
  • Page 164 Runner Purejet pure jet injection The fuel pump is a piston type supplied with a constant current motor. It was designed to supply high pressures with small capacities and low absorption, and is therefore suitable for use on reduced capacity motors.
  • Page 165 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 12- No error present. The pump's electric command circuit is efficient. For a more complete check, proceed with the check on the fuel supply circuit. 13- Fuel pump error in occurred or stored status. Proceed with the check on the pump and the control circuit, paying particular attention to false contacts or uncertain insulation.
  • Page 166 Runner Purejet pure jet injection 19 - Restore the wiring. GO TO point 18 20 - Check the fuel pump control line positive in- sulation. 1 - 14 = 0V YES point 22 NO point 21 21- Restore the wiring. GO TO point 20 22 - Check the fuel pump control line negative in- sulation.
  • Page 167 Runner Purejet pure jet injection 25- A resistance of around 0 Ohm indicates the presence of a short circuit. A resistance signifi- cantly greater than the standard values indicates low conductivity. In these cases, replace the pump. GO TO point 24 26- Keeping the ECU conditions disconnected and pump connector connected, check that with the key switch in the «ON»...
  • Page 168 Runner Purejet pure jet injection COMPONENTS LAYOUT: 1 ECU 2 15A fuses 3 Air injector 4 Fuel injector 5 Bobina A.T. 6 Key switch 7 12V - 9Ah battery A+ under panel B To the magnet flywheel The petrol injector receives the pressurized fuel through the supply system. The ECU commands the injector, controlling both the time and the opening moment.
  • Page 169 Runner Purejet pure jet injection GO TO point 2 1- Connect the scooter diagnostic tester. Select function "active diagnosis". Specific tooling 020460Y Scooter diagnosis and tester 2- Activate the fuel injector diagnostic. Listen for 5 fuel injector activations. Check the diagnostic tester response.
  • Page 170 Runner Purejet pure jet injection 020481Y Control unit interface wiring 3. Check the efficiency of fuse 15A and restore the wiring if necessary. GO TO point 2 4. Check the continuity of the fuel injector control line 3 - white = continuity NO point 5 YES point 6 N.B.
  • Page 171 Runner Purejet pure jet injection 11. If different resistive values are detected, re- place the fuel injector mounting 12. Check the fuel injector winding negative insu- lation. 1 - any pin of the injector > or = 10 Ohm NO point 13 YES point 14 13.
  • Page 172 Runner Purejet pure jet injection coolant temperature sensor circuit Warning: We inform you that some engine malfunctions have recently been dealt with erroneously by re- placing the fuel pump without first checking the correct fitting of the clamps (shown in the picture). Therefore, before replacing the pump follow the procedure given below: 1.
  • Page 173 Runner Purejet pure jet injection to the shunt, just before the pump. The shunt is attached to the bleed tube leading to the upper-half of the tank. The principle of communicating reservoirs guarantees the bleeding of the pump intake right from the first refill.
  • Page 174 Runner Purejet pure jet injection 020617Y Air pressure check kit 3. Attach the fuel pressure control kit onto the supply line. The installation may be carried out either at the pump outlet or at the injector mounting inlet. GO TO point 4 N.B.
  • Page 175 Runner Purejet pure jet injection 8. Using a flat-ended caliper slowly shut the spe- cial tool hose on the injector mounting side. Check that the distributed pressure and absorbed current are within specs. NO point 10 YES point 11 Specific tooling 020616Y Fuel pressure control kit 9.
  • Page 176 Runner Purejet pure jet injection 14. Detach the fuel return duct and prepare an ad- equate container for the collection of fuel. Keeping the ammeter attached to pins 1 - 14 on the interface wiring, run the pump for one minute while turning the key-switch to «ON»...
  • Page 177 Runner Purejet pure jet injection 19. The system is capable of providing the correct fuel supply pressure. N.B. THE PRESSURE FIGURES SHOWN REFER TO A WARM ENGINE. WITH THE ENGINE COLD AND AT IDLE THE PRESSURE FIGURES MAY BE LOWER BY 0.5 BAR, DUE TO LONGER INJECTION CYCLES.
  • Page 178 Runner Purejet pure jet injection GO TO point 26 N.B. A NOTICEABLE PRESSURE LOSS WHICH OCCURS ONLY AFTER A FEW HOURS IS NORMAL. 26. When the fuel supply system is working effec- tively, it is possible to carry out the hydraulic check of the fuel injector.
  • Page 179 Runner Purejet pure jet injection Let the fuel injector open for 15 seconds by jumping pins 3 -1. Measure the fuel output from the injector: standard distribution - 14 cm3 (pressure 2.5 BAR) in 15 seconds NO point 29 YES point 30 29.
  • Page 180 Runner Purejet pure jet injection B + Fixed INJ PJ - 180...
  • Page 181 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 182 Runner Purejet Braking system Rear brake calliper Removal - Disconnect the hydraulic union collecting the oil in an appropriate container. - Loosen the two support calliper clamps. Refitting - On refitting, work in the reverse order and respect the indicated torques. Locking torques (N*m) Rear brake calliper: 20 - 25 Nm Front brake calliper...
  • Page 183 Runner Purejet Braking system Removal - Disconnect the oil line from the calliper, collecting the oil in a container. - Remove the clamps highlighted in the diagram. - On refitting tighten the bolts to the prescribed tor- que. - Perform bleeding procedure on the system. Overhaul - Remove the calliper assembling bolts and take out the internal bodies and components.
  • Page 184 Runner Purejet Braking system CAUTION RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS. AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH. Locking torques (N*m) Screw tightening calliper to the support 20 ÷ 25 Calliper union: 20 ÷...

  • Page 185: Front Brake Disc

    Runner Purejet Braking system Front brake disc Removal - Remove the front wheel loosening the axle clamp. - Unscrew five disk clamps. Refitting - On refitting, position the disc correctly, making sure to turn it in the right direction and apply medium threadblock.
  • Page 186 Runner Purejet Braking system Removal - To facilitate this operation remove the two calliper fixings. With the calliper detached from its support but still connected to the brake fluid line, remove the plastic cover by prising it with a screwdriver. - Remove the outside circlip from the brake pad pin, the leaf spring and the pads.
  • Page 187 Runner Purejet Braking system - DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL. N.B. DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SUR- ROUNDING AIR.
  • Page 188 Runner Purejet Braking system - On refitting, perform the operation in reverse. - Tighten the hydraulic lines to the prescribed tor- que and bleed the circuit. Locking torques (N*m) Hydraulic line torque 13 ÷ 18 N•m Removal - Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac- tuate the brake lever until no more fluid flows out.
  • Page 189 Runner Purejet Braking system Refitting Before fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc.. They should be washed thoroughly in denatured alcohol before proceeding. - Reinstall the individual parts in the reverse order to the removal, paying attention to the correct po- sitioning of the rubber parts in order to ensure leak tightness.
  • Page 190 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 191 Runner Purejet Cooling system Water pump - overhaul - Remove the rpm sensor /coolant delivery hose clamp - Remove the transmission cover - Remove the mixer - Position the tool as shown in the picture N.B. WHEN SECURING THE TOOL, PAY ATTENTION NOT TO OVERLOAD THE PLASTIC IMPELLER.
  • Page 192 Runner Purejet Cooling system - Using the special tool, loosen the impeller shaft turning the spanner clockwise (left-handed thread) - As the thread is fully disengaged, extract the shaft using pliers. Specific tooling 020169Y Water pump crankshaft fitting and re- moval spanner - Using the special hook, remove the sealing ring from its housing as shown in the picture.
  • Page 193 Runner Purejet Cooling system - Lubricate the oil seal and push it home using the special tool as shown in the picture Specific tooling 020168Y Water seal punch mount on half- crankcase 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...
  • Page 194 Runner Purejet Cooling system Removal • Detach the coolant hose from the head, partially draining the system. • Remove the cylinder head. • Remove the two fixing screws and hence the thermostat. Check 1) Visually check that the thermostat is not dam- aged.
  • Page 195 Runner Purejet Cooling system Refitting • Refit the thermostat onto the head, fol- lowing the removal operations in the reverse order, and paying attention in inserting the groove on the thermostat on the reference on the head. COOL SYS - 195...
  • Page 196 INDEX OF TOPICS CHAS HASSIS...

  • Page 197: Rear Rack

    Runner Purejet Chassis Seat - Remove the two screws shown in the picture. Rear rack - Remove the side fairings - Remove the three screws shown in the picture See also Side fairings Rear handlebar cover - Remove the three screws, disconnect the elec- trical connections and the odometer transmission.
  • Page 198 Runner Purejet Chassis Front handlebar cover - Remove the two screws shown in the picture, unhook the joint in the upper part of the handlebar cover between the front and rear part. Pull the front part upwards to prevent damaging the plastic joints, .
  • Page 199 Runner Purejet Chassis Legshield - Remove the side - Remove the front headlight - To remove, loosen the 4 screws shown in the picture, disconnect the electric connections of the turn indicators. The front shield is formed of two perfectly symmetrical parts. See also Side fairings Headlight assy.
  • Page 200 Runner Purejet Chassis Removing the ignition key-switch when on *lock* Remove the shield. - Remove the switch of the key switch. - Make a hole on the block using a drill as shown in the figure. - Insert the wheel cylinder with the key and with the anchoring tab facing down halfway on the lock body taking care that the insertion phase of the key is oriented matching "ON"...
  • Page 201 Runner Purejet Chassis Side fairings Air grid - Remove the screws and detach the air conveyor grille from the side. Air conveyor - Remove the air grille - Loosen the screws shown in the picture. See also Side fairings • Remove the rear grille •...
  • Page 202 Runner Purejet Chassis Helmet bay - Remove the battery - Remove saddle - Remove side - Remove the fuel tank oil mix cap - Remove the electrical cables inisde the battery compartment. - Remove the 4 screws shown in the picture on the front part of the helmet compartment.
  • Page 203 Runner Purejet Chassis Fuel tank - Remove central cover - Loosen the three screws highlighted in the pic- ture, disconnect the piping and the electrical con- nections being careful not to let gasoline spill out. See also Frame central cover Rear central cover Rear closure element - Remove the rear spoiler...
  • Page 204 Runner Purejet Chassis Radiator fan - Remove Central cover - Remove the three radiator fastening screws and the radiator tube clips. The radiator contains liquid so wait for the engine to be cooled down com- pletely to avo-id serious burns before removing it. - On refitting use the specific pliers for the clips.

  • Page 205: Lower Cover

    Runner Purejet Chassis Mixture oil tank - Remove helmet carrier compartment - Remove the two screws shown in the picture - Disconnect the cabling from the oil mix level transmitter - Disconnect the oil pump from the tank. See also Helmet bay Front central cover - Remove the two screws indicated in the picture.
  • Page 206 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 207 Runner Purejet Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Fastenings check - All tightening torques - External fairing screws Electrical system Electrical system - Fill the battery with battery acid, charge it with a suitable charger. - Key switch - Low beam lights, high beam lights, warning lights, parking lights - Headlight adjustment...
  • Page 208 Runner Purejet Pre-delivery IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO EN- SURE ADEQUATE VENTILATION.
  • Page 209 Runner Purejet Pre-delivery Functional inspection − Brake lever excursion. − Throttle excursion and adjustment. − Homogeneous steering turning. PRE DE - 209...
  • Page 210 INDEX OF TOPICS TIME...
  • Page 211 Runner Purejet Time Engine ENGINE Code Action Duration 001001 Eng. from frame - Removal and refit 003057 Engine retainer - Tighten nuts Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase- Replacement TIME - 211...
  • Page 212 Runner Purejet Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001118 Bench bearings - Replacement 001099 Oil seal flywheel side- Replacement 001100 Oil seal clutch side - Replacement TIME - 212...
  • Page 213 Runner Purejet Time Cylinder assy. PISTON - CYLINDER - TEST PROBE ASSEMBLY Code Action Duration 001002 Cylinder-Piston - Replacement 001107 Cylinder/piston - Service /clean TIME - 213...
  • Page 214 Runner Purejet Time Cylinder head assy. INLET MANIFOLD - HEAD Code Action Duration 001056 Head gasket - Replacement 001013 Inlet manifold- Replacement 003056 Head/cylinder - Nuts tightening TIME - 214...
  • Page 215 Runner Purejet Time INJECTOR SUPPORT Code Action Duration 001126 Head - Replacement 001093 Spark plug - Replacement 001057 Thermostat - Replacement 007010 Bleed valve - Replacement 005110 Fuel injector mounting - Replace- ment 005111 Air injector - Replacement 005112 Air injector - Service 001061 O-Ring tube coolant delivery- Re- placement...

  • Page 216: Driven Pulley

    Runner Purejet Time Driven pulley DRIVEN PULLEY Code Action Duration 001110 Driven pulley- Replacement 001012 Driven pulley - Service 001022 Clutch - Replacement 003072 Clutch assembly - Check wear 001155 Clutch bell - Replacement TIME - 216...
  • Page 217 Runner Purejet Time Oil pump OIL PUMP Code Action Duration 001019 Mixer belt - Replacement 001028 Mix gear movement- Replacement 001018 Mixer - Replacement TIME - 217...
  • Page 218 Runner Purejet Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - replace 001066 Driving pulley- Removal and refit 001066 Driving pulley - Service 001011 rear-view belt - Replacement TIME - 218...
  • Page 219 Runner Purejet Time Transmission cover TRANSMISSION COVER - FEMALE SCREW Code Action Duration 001096 Transmission crankcase cover - Re- placement 001135 Transmission cover bearing - Re- placement 001131 Transmission air intake - Replace- ment TIME - 219...

  • Page 220: Water Pump

    Runner Purejet Time Water pump WATER PUMP Code Action Duration 001113 Water pump - Replacement 001062 Pump command shaft - Removal and refit TIME - 220...
  • Page 221 Runner Purejet Time Starter motor STARTER Code Action Duration 001017 Starter pinion - Replacement 001020 Starter motor - change 005045 Starter cable assembly - Replace- ment TIME - 221...

  • Page 222: Flywheel Magneto

    Runner Purejet Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - Replacement 001058 Flywheel - Replacement 001067 Stator - Removal and refit TIME - 222...
  • Page 223 Runner Purejet Time Belt cooling duct BELT REFRIGERATION TUBE Code Action Duration 001132 Transmission air intake pipe - Re- placement 001131 Transmission air intake - Replace- ment TIME - 223...
  • Page 224 Runner Purejet Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body TIME - 224...
  • Page 225 Runner Purejet Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 225...
  • Page 226 Runner Purejet Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement 001015 Air filter box - Replacement 001027 Bodywork / cleaner union- Replace- ment 004122 Cleaner / Throttle body union - Re- placement TIME - 226...
  • Page 227 Runner Purejet Time Frame KICKSTAND FRAME Code Action Duration 004001 Frame- Replacement 006001 Frame - Painting 004004 Kickstand - Replacement 001053 Stand bolt - Replacement TIME - 227...
  • Page 228 Runner Purejet Time Side fairings SIDE FAIRING Code Action Duration 004085 Fairing (1) - Replacement 004012 Rear fairings - Removal and refitting 004059 Spark plug inspection flap - Replace- ment 006008 Rear side panel - Replacement TIME - 228...
  • Page 229 Runner Purejet Time Rear cover LOWER SHIELD FAIRING Code Action Duration 004022 Shield lower section - Replacement TIME - 229...
  • Page 230 Runner Purejet Time Central cover CENTRAL FAIRING Code Action Duration 004011 Central chassis cover - Replacement 004068 Passenger handgrip - Replacement 004056 Upper rear light cover - Replacement 006040 Passenger handle - Paintwork TIME - 230...
  • Page 231 Runner Purejet Time CENTRAL FAIRING Code Action Duration 004132 Semishield - Paintwork 004133 Semishields- Replacement 006039 Semishield - Replacement Mudguard TIME - 231...
  • Page 232 Runner Purejet Time REAR AND FRONT MUDGUARD Code Action Duration 004009 Rear mudguard - Replacement 004002 Front mudguard - Replacement 006003 Mudguard - Painting Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 004109 Fuel tank breather - Replacement 004110 Fuel tank hose - Replacement 005010...
  • Page 233 Runner Purejet Time Tank oil OIL TANK MIXER - DEGASSER Code Action Duration 004017 Oil reservoir - Replacement 004095 Oil reservoir cock - Replacement 005018 Oil reservoir float - Replacement 004091 Oil reservoir hose - Replacement TIME - 233...
  • Page 234 Runner Purejet Time Expansion tank EXPANSION TANK Code Action Duration 007001 Expansion tank - Replacement TIME - 234...
  • Page 235 Runner Purejet Time Radiator RADIATOR Code Action Duration 007002 Water cooling radiator - Replace- ment 007003 Coolant delivery and return pipe - Re- placement 001052 Coolant - Replacement TIME - 235...
  • Page 236 Runner Purejet Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and refit TIME - 236...
  • Page 237 Runner Purejet Time Steering column bearings STEERING THRUST WASHER Code Action Duration 004119 Bearing / upper steering fifth wheel - Replacement 003002 Steering thrust washer - Replace- ment 003073 Steering clearance - Adjustment TIME - 237...

  • Page 238: Handlebar Covers

    Runner Purejet Time Handlebar covers ODOMETER - HANDLEBAR COVER Code Action Duration 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 006013 Front part of handlebar - Paintwork TIME - 238...
  • Page 239 Runner Purejet Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002080 Rear brake oil bleeding system - Re- placement 002067 Rear brake pump - Replacement 002020 Rear brake pipes - Removal and re- fitting 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement HANDLEBAR COMPONENTS...
  • Page 240 Runner Purejet Time Code Action Duration 003061 Accelerator transmission - Adjust- ment 003001 Handlebar - Removal and refit 002060 Throttle grip - Replacement 002059 Right hand grip - Replacement 002024 Front brake pump - Removal and Re- fitting 002018 Front brake pump - Service 005017 Stop switch - Replacement Swing-arm...

  • Page 241: Turn Signal Lights

    Runner Purejet Time SEAT Code Action Duration 004003 Saddle - Replacement Turn signal lights OPTICAL UNIT Code Action Duration 005008 Front headlamp bulbs - Replacement 005002 Front light - Replacement 005044 Front lights cable unit- Replacement TIME - 241...
  • Page 242 Runner Purejet Time FRONT TURN INDICATORS Code Action Duration 005012 Front direction indicators - Replace- ment 005067 Front turn indicator bulb - Replace- ment BACK HEADLIGHT Code Action Duration 005066 Rear light bulbs - Replacement 005005 Tail light - Replacement 005028 Rear light assembly glass - Replace- ment...

  • Page 243: Front Wheel

    Runner Purejet Time Front wheel FRONT WHEEL Code Action Duration 003038 Front wheel axle- Removal and refit 002041 Brake disc - Replacement 002011 Odometer drive - Replacement 004123 Front wheel - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Removal and refit 003040 Front wheel bearings - Replacement Grease tone wheel or drive...

  • Page 244: Rear Wheel

    Runner Purejet Time In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel) Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Removal and refit 003063...
  • Page 245 Runner Purejet Time compressore aria AIR COMPRESSOR Code Action Duration 001168 Air compressor - Replacement 004160 Compressed air hose - Replacement TIME - 245...

  • Page 246: Fuel Pump

    Runner Purejet Time Fuel pump SUPPLY SYSTEM Code Action Duration 004072 Fuel filter - Replacement 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement 004138 Fuel reverse pipe - Replacement TIME - 246...
  • Page 247 Runner Purejet Time Electric devices FRONT ELECTRIC DEVICES Code Action Duration 005113 Plug with contacts - Replacement 005069 Left switch - Replacement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement 005039 Headlight switch - Replacement TIME - 247...
  • Page 248 Runner Purejet Time ELECTRIC DEVICES LOCKS Code Action Duration 004096 Lock series - Replacement 005016 Key switch - Replacement 004010 Anti-theft lock - Replacement ELECTRIC DEVICES Code Action Duration 001069 HV coil - Replacement 001094 Spark plug cap - Replacement 001023 Control unit - Replacement 005001...
  • Page 249 Runner Purejet Time BATTERY ELECTRIC DEVICES Code Action Duration 005052 Fuse - Replacement 005011 Start-up remote control switch - Re- placement 005025 Fuse holder - Replacement TIME - 249...
  • Page 250 Runner Purejet Time BATTERY Code Action Duration 005007 Battery - Replacement 005046 Battery cover - change Transmissions TRANSMISSIONS Code Action Duration 002051 Complete odometer transmission - Replacement 002063 Complete gas command trans. - Re- placement 002054 Complete gas command or splitter trans.

  • Page 251: Brake Callipers

    Runner Purejet Time Brake callipers FRONT BRAKE CALLIPER Code Action Duration 002039 Front brake calliper - Removal and refit 002040 Front brake calliper - Check 002021 Front brake line - Removal and refit 002047 Frt. brake fluid and bleeding circuit- Replacement 003070 Front brake pads / Shoes - Check...
  • Page 252 Runner Purejet Time REAR BRAKE CALLIPER Code Action Duration 003071 Rear brake pads - Wear check 002002 Rear brake pads - Replacement 002068 Rear brake calliper - Check 002048 Rear brake calliper - Replacement 002081 Rear brake disc piping - Replace- ment Fuel tank filler flap TIME - 252...
  • Page 253 Runner Purejet Time GASOLINE DOOR - STEER BLOCK Code Action Duration 004135 Fuel tank lid - Replacement 002082 Fuel tank cap opening drive - Re- placement Helmet bay HELMET HOLDER Code Action Duration 004016 Helmet-compartment - Removal and refit 004054 Seat lock hook - Replacement TIME - 253...

  • Page 254: Rear Wheel Axle

    Runner Purejet Time Rear wheel axle REAR WHEEL AXLE Code Action Duration 001010 Reduction gear-Service 003065 Gear box oil - Replacement 004145 Rear wheel axle - Replacement TIME - 254...

  • Page 255: Front Suspension

    Runner Purejet Time Front suspension FRONT FORK Code Action Duration 003051 Complete fork - Replacement 003041 Fork stanchion - Replacement 003048 Oil seal fork - Replacement 003039 Fork leg mandrels - Replacement 003010 Front suspension - Service TIME - 255...
  • Page 256 Runner Purejet Time Cooling system COOLING SYSTEM Code Action Duration 007009 Head-pump by-pass rubber coupling - Replacement TIME - 256...
  • Page 257 Air filter: 31 Battery: 37, 43, 45, 51 Brake: 182, 184, 185, 187, 251 Control panel: Coolant: 172, 179 Fuel: 32, 163, 203, 232, 246, 252 Headlight: 34, 198, 199 Horn: Hub oil: 30 Identification: 6 Maintenance: 6, 27 Odometer: Shock absorbers: 110 Spark plug: 29 Tank: 203–205, 232–234, 252...

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