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Derbi GP1 125-250 c.c. Workshop Manual

Gp1 125-250 c.c..
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W
ORKSHOP MANUAL
GP1 125-250 c.c.

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Table of Contents

   Summary of Contents for Derbi GP1 125-250 c.c.

  • Page 1 ORKSHOP MANUAL GP1 125-250 c.c.
  • Page 2 The intention is to provide as much assistance as possible to mechanics working for our brand’s dealers and sub-dealers. Due to its constant commitment to improving its products, DERBI - NACIONAL MOTOR, S.A.U. Sociedad Unipersonal reserves the right to introduce any modifications it deems fit, without prior warning.
  • Page 4 Pág. 1 INTRODUCTION Pág. 8 GENERAL INFORMATION Pág. 9 GENERAL TECHNICAL DATA Pág. 30 RECOMMENDED TOOLS Pág. 40 PERIODIC MAINTENANCE DISMANTLING Pág. 64 SEAT SIDE TRIM Pág. 64 COWLING Pàg. 65 COWLING BOTTOM COVER Pág. 65 WATER-OIL TANK COVER Pág. 65 SIDE COVERS Pág.
  • Page 5 Pág. 82 REFITTING THE CLUTCH Pág. 85 REFITTING THE DRIVEN PULLEY Pàg. 85 DRIVE-VELT Pág. 86 REMOVING THE DRIVING PULLEY Pág. 87 INSPECTING THE ROLLERS CASE Pág. 88 REFTTING THE DRIVING PULLEY Pág. 89 REFITTING THE TRANSMISSION COVER Pág. 90 END GEAR Pág.
  • Page 6 Pág. 111 INSPECTING THE PISTON RING Pág. 112 REMOVING THE PISTON RING Pág. 113 CHOOSING THE GASKET Pág. 115 COMPRESSION RATIO VERSION 250 Pág. 116 REFITTING THE PISTON RINGS Pág. 116 REFITTING THE CYLINDER Pág. 117 INSPECTING THE CYLINDER HEAD Pág.
  • Page 7 FORK, SHOCK ABSORBER. ENGINE SUPPORT AND STAND Pág. 173 DISMANTLING FRONT SUSPENSION Pág. 175 INSPECTING THE FRONT FORKS Pág. 179 DISMANTLING Pág. 179 INSPECTION Pág. 180 SWING-ARM Pág. 181 CHECKING THE SWINING ARM Pág. 181 EXHAUST BRACKET Pág. 182 OVERHAUL Pág.
  • Page 8 Pág. 224 SENSORS AND INDICATORS Pág. 225 TURN INDICATORS AND HORN Pág. 226 IGNITION CIRCUIT Pág. 226 SPARK PLUG Pág. 227 STATOR CHECK Pág. 227 VOLTAGE REGULATOR CHECK Pág. 230 FUSES Pág. 230 DISMANTLING THE BATTERY Pág. 232 BATTERY - INITIAL CHARGE Pág.
  • Page 9 MAINTENANCE REGULATIONS MAINTENANCE REGULATIONS - Use genuine DERBI spare parts and lubricants recommended by the manufacturer. Non-genuine or unau- thorised parts may damage the engine. Always use new gaskets and oil seals during re-assembly.
  • Page 10 MACHINE ENGINE PREFIX FRAME PREFIX GP1 125 c.c. GP1 125 c.c. M434M VTHPS1A1A GP1 250 c.c. GP1 250 c.c. M237M VTHPT1A1A IMENSIONS AND WEIGHT SPECIFICATIONS DESC. / QUANTITY Maximum length 1930 mm. Maximum height 1225 mm. Length between axles 1375 mm. Handlebar width 705 mm.
  • Page 11 NGINE SPECIFICATIONS DESC. / QUANTITY Compresion ratio (250) 10,5-11,5: 1 Keihin Carburettor (125 - 250) CVEK-30 Walbro Carburettor (125) WVF 7G* 0 29 Walbro Carburettor (250) WVF-7S* Idle speed 1650 ±50 r.p.m. Adjustment CO 3,8 ± 07 Air filter Sponge-type damped eith a 50% for filters. Oil - 50% unleaded petrol misture Electric starter motor Starter system...
  • Page 12 LECTRICAL SYSTEM LECTRICAL COMPONENTS SPECIFICATIONS DESC. / QUANTITY Electronic with capacitive discharge (CDI) and variable Ignition type advance with separate HT coil. Ignition advance (before T.D.C) 125 10°±1° at 2000 r.p.m. - 34°±1° at 6000 r.p.m. Ignition advance (before T.D.C) 10°...
  • Page 13 HEELS AND TYRES SPECIFICATIONS DESC. / QUANTITY Front wheel rim Aluminium alloy Rear wheel rim In light alloy Front tyre 120 / 70 x 14” Rear tyre 120 / 60 x 14” Tyre pressure front wheel (cold) 1,9 bar Tyre pressure rear wheel (cold) 2,0 bar Tyre pressure rear/front wheel (driver and 2,0 / 2.2 bar...
  • Page 14 Flowing through the hole shown in the figure, the air reaches the second filter, «B», At this point, the tiltered air enters the membrane device, so to be channelled towards the head. Flowing through a rigid pipe, flanged to the head, the se- condary air reaches the exhaust duct thus providing oxygen addition to the unburnt gases just before they enter the ca- taiytic converter.
  • Page 15 The working principie ofthe SAS for Quasar 250 cc Euro 2 engines is entirely similar to the SAS employed on 2-stroke engines. The main differences are the following: Secondary air enters directly into the exhaust duct on the cylinder head, instead of entering through the exhaust pipe as in two-stroke engines.
  • Page 16 HEIHIN ARBURATTOR Version 125 SPECIFICATION DESC. / QUANTITY Depresione type CVEK30 Printing on the body Device CUT-OFF Not present Max. jet Minimum jet Max. air jet Minimum air jet Idle mixture adjusment screw initial opening 2 ±1/4 Conical pin Ø 2,450 Emulsifier nozzle Ø...
  • Page 17 WALBRO ARBURADOR SPECIFICATION DESC. / QUANTITY Starter jet Starter pin diameter Ø 1,78 Starter device resistance ~ 40Q Ø 29 (30,3x27,0) Choke Throttie valve Ø 33 Choke máximum cone Ø 48,0 HEIHIN ARBURATTOR Version 250 SPECIFICATION DESC. / QUANTITY CVEK30 Depression type Printing on the body CUT-OFF device...
  • Page 18 WALBRO ARBURATTOR Version 250 SPECIFICATION DESC. / QUANTITY WVF-7S* Depression type Printing on the body CUT-OFF device Presente Max jet Minimum jet Max air jet Mínimum air jet Gas valve spring 120 gr Idle mixture adjustment screw initial opening 3±½ Conical pin Tacche dall’alto spillo cónico Emulsitier nozzle...
  • Page 19 HASSIS TIGHTENING TORQUES TORQUES TORQUES DESCRIPTION SEALER (N.M) (M.KG) M8X125 8.8 FRONT FRAME-CHASSIS SECUR.DEVICE 1,7÷1,9 17÷19 M8X125 8.8 SUBCHASSIS-CHASSIS SEC.DEVICE 1,7÷1,9 17÷19 M10x150 12.9 TOP SHOCK ABSOR.-CHASSIS SEC.DEVICE 4,5÷5,5 45÷55 M10x150 12.9 BOTTOM SHOCK ABSOR.-ENG. SEC.DEV. 4,5÷5,5 45÷55 M14x200 8.8 FRONT ENG. SUPPORT-CHASSIS SEC.DEV. 7÷8 70÷80 M10X150 8.8 REAR ENG.SUPP-FRONT ENG.SUPP.
  • Page 20 XAUST PIPE NAME TORQUE IN Nm 15,5 ÷ 18,5 Screw clamping manifold to silencer Screw clamping heat shield to silencer 5 ÷ 6 Exhaust gas intake screw 22 ÷ 26 33 ÷ 41 Screw fixing silencer support arm to crankcase Exhaust pipe/support bracket fixing screw.
  • Page 21 YLINDER HEAD NAME TORQUE IN Nm Tappet adjustment lock nut 6 ÷ 8 10 ÷ 14 Timing chain tightener sliding block screws Start up mass bell screws 11 ÷ 15 11 ÷ 15 M6 central screw fastening washers on cam shaft (125 cc) Timing beit tightener support screw 11 ÷...
  • Page 22 NGINE CRANKCASE AND SHAFT NAME TORQUE IN Nm 4 ÷ 6 Engine crankcase inside head screws (transmission side half shaft) Engine crankcase coupling screws 11 ÷ 13 Starter motor screws 11 ÷ 13 3,5 ÷ 4,5 Crankcase timing cover screws OOLING NAME TORQUE IN Nm...
  • Page 23 VERHAUL DATA SSEMBLY CLEARANCES YLINDER ISTON ASSY CATEGORIES COUPLING 125 PLAY ON NAME PLAY CYLINDER PISTON INITIALS FITTING Cylinder 56,945 ÷ 56,952 0,045-0,059 57+0,025±0,003 56,997 ÷ 57,004 Cylinder 56,952 ÷ 56,959 0,045-0,059 57+0,025±0,003 57,004 ÷ 57,011 Piston 56,959 ÷ 56,966 0,045-0,059 56,959±0,014 57,011 ÷...
  • Page 24 COUPLING CATEGORIES ENGINE 250 NAME PLAY CYLINDER PISTON INITIAL PLAY ON FITTING Cylinder Cylinder 72+0,018±0,010 71,990 ÷ 71,997 71,953 ÷ 71,960 0,030-0,044 Cylinder Cylinder 72+0,018±0,010 71,997 ÷ 72,004 71,960 ÷ 71,967 0,030-0,044 Piston Piston 71,967±0,014 72,004 ÷ 72,011 71,967 ÷ 71,974 0,030-0,044 Piston Piston...
  • Page 25 OVERSIZES ENGINE 250 NAME DESCRIPTION DIMENSIONS INITIALS QUANTITY Compression lining 72 x 1,5 0,15 ÷ 0,30 Scraper ring lining 72 x 1 0,20 ÷ 0,40 Scraper ring lining 72 x 2,5 0,20 ÷ 0,40 RANKCASE RANKSHAFT ONNECTING ROD CRANKCASE - DRVING SHAFT - BENCH HALF BEARING NAME DESCRIPTION DIMENSIONS...
  • Page 26 ITTING CLEARANCE Driving shaft/case axial clearance: Standard clearance 0,15 ÷ 0,40mm (cold engine). CARNCSHAFT - CRANKCASE AXIAL CLEARANCE/CARTER NAME DESCRIPTION DIMENSIONS INITIALS QUANTITY Half shaft transmission side 16,6+0-0,05 D = 0,20 ÷ 0,50 Half shaft flywheel side 16,6+0-0,05 D = 0,20 ÷ 0,50 Conecting rod 18-0,10-0,15 D = 0,20 ÷...
  • Page 27 LOT PACKING SYSTEM Characteristics Compresion ratio - 125cc verion Rc: 11,50÷13:1 The length «A» to be measured refers to the pistón protrusion. It indicates the amount by which the surface formed by the pistón crown tops the surface formed by the upper parí of the cylinder. The more the pistón descends into the cylinder, the less the base gasket to be applied (to recover the compression ratio) will be and vice versa.
  • Page 28 LOT PACKING SYSTEM Characteristics Compresion ratio - 125cc verion Re: 11,50÷13:1 The length «A» to be measured refers to the pistón protrusion. It indicates the amount by which the surface formed by the pistón crown tops the surface formed by the upper part of the cylinder. The more the pistón descends into the cylinder, the less the base gasket to be applied (to recover the compression ratio) will be and vice versa.
  • Page 29 ISTEMA DE MONTAJE DE ESPESORES Características Técnicas Relación de compresión versión 250 Re: 10,5-11,5 NOTE MOUNT ACCORDING TO THE MEASUREMENT (A) OBTAINED NOTE MEASUREMENT (A) MUST BE TAKEN WITHOUT TRIM MOUNTED BETWEEN THE CASING AND THE CYLINDER, AFTER HAVING PUT THE COMPARATOR TO ZERO, WITH ITS SUPPORT, ON A FLAT PLANE.
  • Page 30 VERSIZES OVERSIZES ENGINE NAME DESCRIPTION DIMENSION INITIALS QUANTITY Compression lining 1° greater 57,2 x 1 0,15 ÷ 0,30 First uprated scraper ring lining 0,10 ÷ 0,30 57,2 x 1 First uprated scraper ring lining 57,2x2,5 0,15 ÷ 0,35 Second uprated compression lining 0,15 ÷...
  • Page 31 PREPARATION FOR REMOVAL AND DISMANTLING PREPARATION FOR REMOVAL AND DISMANTLING 1. Remove all the dirt, grime, dust and other foreign material before removing and dismantling. 2. Use properly cleaned tools and equipment. See “SPECIAL TOOLS”. 3. On dismantling the motorcycle, always keep paired parts together.
  • Page 32 EPLACEMENT PARTS 1. Use only genuine DERBI spare parts. For all lubrication tasks use oils and greases recommended by DERBI. Other makes make seem similar in their function and appearance, but are inferior in quality. EALS EALS RETAINING RINGS AND O...
  • Page 33 OCKING RINGS 1. Examine all the locking rings carefully before fitting. Always replace the gudgeon pin circlips after every use. Re- place distorted locking rings. On fitting a locking ring (1), ensure that the sharp edge (2) is on the opposite side to the force to be applied to it.
  • Page 34 STORES CODE DESCRIPTION IMAGE 020412Y 15mm guide Magentic stand and 020335Y comparator 020565Y Compass flywheel stop spanner 020439Y 17mm guide 020359Y 42 x 47mm hub bearing fitting adaptor 020363Y 20mm guide 002095Y Engine support 008564Y Flywheel extractor 020434Y Oil presure gauge connection...
  • Page 35 STORES CODE DESCRIPTION IMAGE 020382Y011 Bushing (valve remover) 020424Y Driven pulley roller casing drift 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Valve sealing ring drift 52 x 55mm adaptor 020360Y 020364Y 25mm guide 020375Y Adapter 28 x 30mm...
  • Page 36 STORES CODE DESCRIPTION IMAGE 020376Y Handle for punches Driven half pulley spring com- 020444Y pressor tool 020330Y Stroboscopic gun fot two-and four-stroke engines 001467Y035 Bell 020368Y Driving pulley stop wrench Immobilizer control test 020319Y 020287Y Piston band clamps (engine 125 c.c) 020263Y Protective sheath...
  • Page 37 STORES CODE DESCRIPTION IMAGE 020262Y Crankcase detachment plate Pin retainers installation tool 020430Y (engine 125cc) 020428Y Piston position check support 020426Y Piston fitting fork 020425Y Flywheel-side oil guard punch Driven pulley stop key 020423Y 020414Y 28 mm guide - Hub bearing asembly 020393Y Piston band clamps...
  • Page 38 STORES CODE DESCRIPTION IMAGE 020382Y Tool for removing valve cotters equipped with part 012 10mm guide 020455Y 020442Y Pulley stop wrench 020440Y Water pump overhaul tool 020329Y Pump 32 x 35 mm adaptor 020357Y 020409Y Multimeter adpater (Peak vol- tage measurement) 020456Y Ø...
  • Page 39 STORES CODE DESCRIPTION IMAGE 020332Y Digital rpm counter Crankshaft aligning tool 020074Y 002465Y Pliers dor snap rings 020454Y Pin retainers installation tool 020622Y Transmission-side oil guard punch Adapter ring 020444Y011 020444Y009 45 x 55 wrench 001467Y Bell...
  • Page 40 STORES CODE DESCRIPTION IMAGE 001467Y013 15mm pliers Adapter ring 020444Y008 020244Y Drift Ø 15 020115Y Drift Ø 18 020271Y Slient-block installation / remo- val tool Flywheel stop key 020627Y 020467Y Flywheel estractor 020626Y Driving pulley stop key...
  • Page 41 AINTENANCE CHART EVERY 3000 KM EVERY 3000 KM ACTION Engine Oil Level Check/Top up EVERY 2 YEARS EVERY 2 YEARS ACTION Cooling Fluid Replacement Brake fluid Change Secondary air filter (external - internal) - Cleaning (125) AT 1.000 KM OR 4 MONTHS ACTION Engine oil Replacement...
  • Page 42 AT 6.000 KM OR 12 MONTHS ACTION Transmission Belt Check Cooling fluid level Check Brake pads Check condition + wear Brake fluid level Check Electrical system and battery Check Tires-inflation and wear Check Vehicle and brake test Road test AT 12.000 KM OR 24 MONTHS AND 60.000 KM ACTION Engine oil Replacement...
  • Page 43 AT 18.000 KM AND 54.000 KM ACTION Engine oil Replacement (125) Hub oil level Check Spark Plug/Electrodes distance Check Air Filter Cleaning Oil filter Replacement (125) 125 cc Valve Play Check 250 cc Valve Play Check Roller support sliding blocks / Varistor rollers Check Cooling fluid level Check Radiator...
  • Page 44 AT 24.000 KM AND 48.000 KM ACTION Electrical system and battery Check Headlight Adjust Tires-inflation and wear Check ‘ Vehicle and brake test Road test Transmission Belt Check (250) AT 30.000 KM. 42.000 KM AND 66.000 KM ACTION Hub oil level Check Spark Plug/Electrodes distance Check...
  • Page 45 AT 36.000 KM ACTION Cooling fluid level Check Radiator External cleaning/Check Steering Adjust Brake levers Grease Brake pads Check condition + wear Flexible brake lines Change Brake fluid level Check Transmissions Lubricate Nuts, bolts and fasteners Check Suspensions Check Electrical system and battery Check Headlight Adjust...
  • Page 46 AT 72.000 KM ACTION Transmissions Lubricate Nuts, bolts and fasteners Check Suspensions Check Electrical system and battery Check Headlight Adjust Tires-inflation and wear Check Secondary air filter (250) Cleaning Vehicle and brake test Road test...
  • Page 47 Check level / top up every 3000 km ENGINE OIL ENGINE OIL 125 C.C. ENGINE OIL 250 C.C. HUB OIL LEVER DRIVE BELT 125 C.C. DRIVE BELT 250 C.C. TRANSMISSION OIL FILTER 125 C.C. OIL FILTER 250 C.C. AIR FILTER Check every 2 years SECONDARY OIL FILTER 125 C.C.
  • Page 48 ARBURETTOR - Disassemble all carburettor components, accurately wash them in solvent, then dry them with compressed air. To ensu- re thorough cleaning, pay special attention to the passages in the carburettor body. - Carefully check the condition of all components. - The throttle must slide freely in the chamber, if the play is excessive because or wear-replace the throttle.
  • Page 49 HECKING THE SPARK ADVANCE - To check the ignition advance, use the stroboscopic lamp with induction collet connected to the spark plug power su- pply cable. - Connect the induction collet according to the right polarity (the arrow on the collet must be facing the spark plug).’ - Set the lamp selector to the central position (1 spark = 1 driving shaft revolution as in 2 stroke engines).
  • Page 50 - Remove the transmission cooling air inlet, shown in the pic- ture. - Using a screwdriver rotate the fan, mounted onto the drive pulley, until the marking on the flywheel is aligned with that stamped on the fly-wheel cover, as shown in the picture. - Mark the alignment between fan and transmission cover on the transmission side, as shown in the picture.
  • Page 51 - Check that the advance degrees match the revolution speed as indicated in the tables. - In case of abnormal values, check the Pick-Up and the control unit supplies (positive-negative); replace the control unit, if required. - A new control unit prevents the engine from rotating at over 2,000 rpm. - The programmed control unit allows the engine revolution within the prescribed limits.
  • Page 52 VERSION 250 VERSION 250 SPARK ADVANCE VARIATION SPECIFICATION DESC./QUANTITY Tripping threshold First threshold : 9600 ±50 Second threshold : 9800 ±50 Restoration threshold First threshold : 9500 ±50 Second threshold : 9700 ±50 First threshold : 1 spark out of 7 Spark suppression Second threshold: 2 sparks out of 3...
  • Page 53 PARK PLUG PARK PLUG - Put the vehicle on the central stand. - Open the door on the left side of the vehicle by levering in the recess in the lower part of the door after removing the screw. - Disconnect the spark plug HV cable cap. - Unscrew the spark plug with the spanner provided.
  • Page 54 UB OIL UB OIL Check that there is oil in the rear hub. (quantity of oil contai- ned ~ 250 cc). Proceed as follows in order to check the hub oil level: 1) Take the vehicle to a flat area and rest it on the support. 2) Unscrew the oil bar «A», dry it with a clean cloth and rein- sert it, screwing it in completely.
  • Page 55 HECK - Move the vehicle to a flat ground and rest it on the stand. - Unscrew the oil bar, dry it with a clean cloth and reinsert it, screwing it in thoroughly. - Extract the bar and check that the oil level reaches the se- cond notch of the bar from the bottom.
  • Page 56 N.B. CHECK AND IF NECESSARY BLOW THE AIR FILTER EVERY 6,000 KM. DIRECT THE AIR JET FROM THE INSIDE TO THE OUTSIDE OF THE FILTER (I.E. IN THE OPPOSITE DIRECTION TO THE AIR FLOW DURING NORMAL ENGINE OPERATION). EVERY 6,000 KM, DURING THE SCHEDULED SERVICE, RE- MOVE THE RETAINER, TAKE OFF THE RUBBER CAP FROM UNDER THE FILTER BOX AS SHOWN IN THE FIGURE AND DRAIN ANY OIL RESIDUES.
  • Page 57 NGINE OIL NGINE OIL REPLACEMENT The engine oil should be replaced after the first 1,000 km, and then every 6,000 km for the 125cc version and 12,000 km for the 250cc version. The engine must be drained through the net filter draining cap «B» on flywheel side; in addition, to facilitate the drainage, oil dipstick «A»...
  • Page 58 Perform this operation when the engine cold, as des- cribed below: 1) Put the vehicle on its central stand on a flat surface. 2) Unscrew dipstick “A”, dry it with a clean cloth and refit by screwing it completely. 3) Remove the dipstick again and check that the oil level is between the MAX and MIN marks on the dipstick;...
  • Page 59 IL PRESSURE WARNING LIGHT IL PRESSURE WARNING LIGHT Oil pressure warning light. A warning light on the instrument panel comes on when the ignition key is turned to the “ON” position. The light must go out after the engine has started. Should the warning light come on while braking, idling or cornering, check the oil level and the lubrication system as soon as possible.
  • Page 60 HECKING THE VALVE CLEARANCE HECKING THE VALVE CLEARANCE -To check the valve clearance, you have to make the point references coincide -Check that the clearance between the valve and register co- rresponds to the values shown using a proper thickness gau- ge.
  • Page 61 RAKING SYSTEM RAKING SYSTEM Level check Proceed as follows: - Rest the vehicle onto its centre-stand and align the han- dlebars; - Check the liquid level through the inspection hole «A». A certain decrease in the liquid level is due to the wear of the pads.
  • Page 62 EADLIGHT ADJUSTMENT EADLIGHT ADJUSTMENT Proceed as follows: 1. Position the vehicle in riding conditions, and with the tyres inflated at the prescribed pressure, on a horizontal surface 10m away from a half-lit white screen, ensuring the vertical axis of the vehicle is perpendicular to the screen; 2.
  • Page 63 - Remove the two screws shown in the picture. - Remove the filter shown in the picture. - Inspect the gasket. - Ensure the SAS filter box is not cracked or deformed. - Accurately clean the SAS filter. In the event of break-ups or abnormal deformations, proceed with the replacement.
  • Page 64 - Ensure the SAS filter box is not cracked or deformed. - Inspect the packing. -Accurately clean external and internal filters. In the case of break-ups or abnormal deformations, proceed with the replacement - Ensure the manifold channelling secondary air into the head is not cracked, deformed, or has undergone overheats.
  • Page 65 1. SEAT SIDE TRIM • Extract the 3 securing screws (2 Philips 3.6x14 self- tappers and one 5x16 Allen M3) from each cover. 2. COWLING • Extract the 6 screws (5x12 Allen M3) from under the cowling. - Extract the drawer for the tool kit and its cover, by removing the 2 Philips screws with washers.
  • Page 66 3. LOWER COWLING COVER • Extract the 2 securing screws (Philips 6x16 with was- her) N.B. TO CONTINUE WITH THE HELMET HOLDER WE NEED TO CONTINUE DISMANTLING THE FRONT PART, SIN- CE THE PETROL TANK FRONT BREATHER PIPE PASSES THROUGH THE HELMET HOLDER. 4.
  • Page 67 6. SHIELD INNER COVER • Extract the 2 screws (5x12 Allen M3). • Extract the 3 top screws (2 Philips 3.6x14 self-tappers and one6x16 Allen screw with washer). 7. BATTERY COVER • Extract the Philips screw and separate the cover from the 2 securing flaps.
  • Page 68 • After extracting the 6 side screws and the central (Allen M3 5x12) screw from the tank cover, lift up the tank cover. 8. HELMET CARRIER • Remove the battery and cables. • Extract the 6 securing screws (2 Philips 8x45, 2 Philips 6x19 with washer and 2 8x25 bolts), the petrol tank co- ver, the breather pipe and the seat opening cable.
  • Page 69 9. FOOTRESTS • Remove the 5 securing screws (2 Philips 6x16 with large washer, 2 Philips 6x16 with small washer and 1 Philips 4.8x25 self-tapper), and the one joining the two fairings. 10. SIDE COVERS • Remove the 2 securing screws (1 Philips 6x16 with l washer and 1 Philips 3.6x10 self-tapper), and the turn indicator wire.
  • Page 70 XHAUST ASSY XHAUST ASSY EMOVAL EMOVAL - Unloose the two fixings of the exhaust manifold on the head. - Unloose the 3 screws fixing the muffler to the supporting arm. - Remove the muffler assembly. - For the reassembly, follow the operations indicated above in the reverse order, complying with the tightening torques.
  • Page 71 - Remove the throttle cable. - Detach the air filter bellow and manifold shown in the fi- gure. - Detach engine earth cable. - Disconnect the electrical devices on the carburettor and the starter motor power cord. - Detach the inlet and outlet carburettor fuel lines and the cooling circuit hoses (head outlet and thermostat inlet).
  • Page 72 UTOMATIC TRANSMISSION UTOMATIC TRANSMISSION RANSMISSION COVER To remove the transmission cover it is necessary to remove the plastic cover first, using a screwdriver on the special gui- des. Using the clutch bell lock wrench shown in the figure, remove the driven pulley axle locking nut and washer. Specific tooling 020423Y driven pulley stop key - Remove the cap/bar of the engine oil filling hole.
  • Page 73 - Remove the 5 screws located on two different surfaces and the case. EMOVING THE DRIVEN PULLEY SHAFT BEARING EMOVING THE DRIVEN PULLEY SHAFT BEARING - Remove the snap ring from the cover internalside. - Remove the bearing from the case using: Specific tooling 020376Y Handle for punches 020375Y Adapter 28 x 30 mm...
  • Page 74 AFFLE ROLLER LASTIC ROLLER - To reassemble, install the roller with the containment edge on the engine crankcase side. - Tighten the wrench at the prescribed torque. - Check that the roller is free from wear and that itrotates freely. - Remove the special fixing screw as shown in the figure.
  • Page 75 Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter 15 and 17 mm). - Lock using the original spacer and nut. - Place the bell/shaft assembly on the support to check the driving shaft alignment.
  • Page 76 - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to release and tighten the clutch nut. - Using the specific wrench 46x55 component n° 9, remove the clutch fixing nut. - Separate the components of the driven pulley (clutch, fan and spring with plastic rest).
  • Page 77 NSPECTING THE CLUTCH C U C - Check the thickness of the clutch mass friction material. - The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.DIFFERENT CONDITIONS MAY CAUSE THE CLUTCH TEARING.
  • Page 78 EMOVING THE DRIVEN HALF PULLEY BEARING - Check that there is no wear and/or noise; if not, replace. - Remove the lock ring using two flat blade screw-drivers. - Suitably support the pulley bushing from the threaded side on a wooden surface. - Remove the ball bearing as shown in the figure, using a pin and a hammer.
  • Page 79 Version 250 - Measure the pulley bushing outside diameter. - Check that the contact surface with the belt is free from abnormal wear. - Check the riveting. - Check the belt contact surface planarity. Characteristic Minimum diameter half-pulley Minimum admissible diameter: Ø 40,96 mm Standard diameter half-pulley Standard diameter: Ø...
  • Page 80 - Check that the surface of contact with the belt does not show abnormal wear. - Check the functionality of the riveting. - Check the planarity of the belt surface of contact. MOBILE LINE HALF PULLEY DIMENSIONS SPECIFICATION DESC./QUANTITY Wear limit 0,3 mm Standard diameter Ø...
  • Page 81 EFITTING THE DRIVEN PULLEY Version 125 - Insert the new oil guards and O-Rings on the mobile half- pulley. - Slightly grease the O-Rings (A) shown in the figure. - Install the half pulley on the bushing using the specific tool - Check that the pins are free from wear and reassemble into the relative slits.
  • Page 82 Version 250 - Insert the new oil guards and O-Rings on the mobile half- pulley. - Slightly grease the O-Ring «A» shown in the figure. - Install the half pulley on the bushing using thespecific tool. - Check that the pins are free from wear and reassemble into the relative slits.
  • Page 83 EFITTING THE CLUTCH C U C - Support the driven pulley spring compressor specific tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position «C» on the inside. - Introduce the adapter ring n° 11 with the chamfering facing upwards.
  • Page 84 N.B. DURING THE SPRING PRE-LOADING STEP, BE CAREFUL NOT TO DAMAGE THE SPRING PLASTIC ABUTMENT AND THE BUSHING THREADING. N.B. FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMME- TRIC; THE SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH. Specific tooling 020444Y Driven half pulley spring compressor tool 020444Y011 Adapter ring 020444Y009 wrench 46 x 55...
  • Page 85 - Insert the pulley unit with the belt into the tool. - Slightly pre-load the spring. - Make sure that the clutch is perfectly inserted into the adap- ter ring before proceeding to tighten the clutch nut. - Place the tool into the vice with the control screw in hori- zontal axis.
  • Page 86 EFITTING THE DRIVEN PULLEY - Reinstall the clutch bell and the spacer. RIVE RIVE BELT BELT - Ensure the drive-belt is not damaged. - Check the drive-belt width. Characteristic Driving belt minimum width 21.5 mm Driving belt standard width 22,5±0,2 mm Driving belt 250 4T - minimum width 19,5 mm Driving belt 250 4T - standard width...
  • Page 87 EMOVING THE DRIVING PULLEY Driving pulley removal (125) - Using the specific tool, remove the nut with the built-in spring washer, the drive for the versions with kick-starter, and the steel washer. - Remove the fixed driving half-pulley. - Remove the steel separation washer from the bushing. Specific equipment and tools: 020368Y driving pulley stop wrench VERSION 250...
  • Page 88 - Remove the fixing nut and washer. - Remove the fixed driving half pulley. NSPECTING THE ROLLERS CASE NSPECTING THE ROLLERS CASE - Ensure the internal bearing, shown in the figure, is not ab- normally worn and measure the internal diameter. - Measure the external diameter of the pulley sliding bus- hing, shown in the figure.
  • Page 89 Sliding shim cylinder: Standard Diameter Ø 25,959 - 25,98 mm Sliding shim cylinder: Min. Allowed diameter Ø 25,95 mm Roller (125cc): Standard diameter Ø 18,9 - 19,1 mm Roller: Standard Diameter Ø 20,5-20,7mm Roller (125cc): Minimum diameter Ø 18,5 mm Roller: Min.
  • Page 90 - Turn the engine by hand to obtain a minimum tension of the belt. CAUTION IT IS VERY IMPORTANT TO INSTALL THE FIXED DRIVING HALF-PULLEY WITH THE BELT TOTALLY FREE TO PREVENT A FALSE LOCKING OF THE DRIVING HALF-PULLEY. Specific tooling 020368Y driving pulley stop wrench Locking torques (N*m) Driving pulley screw 75 ÷...
  • Page 91 - Replace the steel washer and the driven pulley nut. - Tighten the nut at the prescribed torque using the lock wrench and the dynamometric wrench tools. - Replace the plastic cover. Specific tooling 020423Y driven pulley stop key Locking torques (N*m) Cover screws 11-13 Driven pulley axis 54 ÷...
  • Page 92 EMOVING THE HUB BEARINGS - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. - To remove the 3 15-mm bearings (2 on the crankcase and 1 on the hub cover) use the specific removing tool. Specific tooling 001467Y01315-mm pliers EMOVING THE WHEEL AXLE BEARINGS...
  • Page 93 EMOVING THE DRIVEN PULLEY SHAFT BEARING - If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the transmission cover and the clutch unit as described before. - Extract the driven pulley shaft from the bearing. - Remove the oil guard using a screwdriver from the inside of the bearing, and being careful not to damage the seat, make it slide out from the belt transmission side.
  • Page 94 EFITTING THE WHEEL AXLE BEARING EFITTING THE WHEEL AXLE BEARING - Place the hub cover on a wooden surface. - Warm the cover case by the specific thermal gun. - Install the wheel axle bearing using the modular punch as shown in the figure.
  • Page 95 Specific tooling 020151 Y Air heater 020376Y Handle for punches 020359Y 42 x 47 mm hub bearing fitting adaptor 020412Y 15 mm guide N.B. TO INSTALL THE BEARING ON THE COVER, SUITABLY SU- PPORT THE COVER BY THE COLUMN KIT Replace the driven pulley axle bearing using the modular punch as shown in the figure.
  • Page 96 EFITTING THE HUB BEARINGS EFITTING THE HUB BEARINGS - Install the 3 shafts in the engine crankcase as shown in the figure. EFITTING THE HUB COVER EFITTING THE HUB COVER - Install a new gasket with the centring dowels. - Seal the vent pipe gasket using black silicone sealant. - Install the cover checking the correct position of the vent pipe.
  • Page 97 Version 125 - Remove the clamp fastening the coupling to the cylinder. - Remove the 10 clamps. - Remove the flywheel cover. EMOVING THE STATOR Version 125 - Remove the oil minimum pressure switch electric terminal. - Remove the 2 Pick-Up screws and the screw of the wiring fixing bracket, along with the 2 stator fixing screws shown in the figure.
  • Page 98 EFITTING THE STATOR Version 125 - Replace stator and flywheel performing the operations for removal in the reverse order and tighten the fixing screws at the prescribed torque. - Place the wiring as shown in the figure. - Stator and Pick-Up screws N.B.
  • Page 99 - Position the keying clamp on the driving shaft and direct the end as shown in the figure. - Position the water pump shaft by referring to the transmis- sion gear seat as shown in the photo. - Reassemble the cover on the engine and tighten the screws to the prescribed torque - Perform the operations for removal in the reverse order.
  • Page 100 Version 250 - Remove the two screws shown in the figure. - Extract the motor from its seat. EMOVING THE FLYWHEEL MAGNETO EMOVING THE FLYWHEEL MAGNETO - Hold the flywheel using the adjustable spanner. - Remove the lock-nut. - Extract the flywheel. CAUTION USING A DIFFERENT WRENCH COULD DAMAGE THE STA- TOR COILS.
  • Page 101 - Line up the 2 holes on the flywheel as shown in the photo - Tighten the guide shim cylinder that is part of the specific flywheel stop key on the flywheel as shown in the photo. - Insert the specific flywheel stop key into the flywheel as shown in the photo.
  • Page 102 NSPECTING THE FLYWHEEL COMPONENTS NSPECTING THE FLYWHEEL COMPONENTS - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. EFITTING THE FLYWHEEL MAGNETO EFITTING THE FLYWHEEL MAGNETO - Install the flywheel being careful to the proper introduction of the key.
  • Page 103 - Insert the free wheel on the flywheel as shown in the pic- ture. - Hence refit the flywheel with the intermediate gear and the free wheel. - Using the special flywheel retaining tool, tighten the lock- nut to the prescribed torque. - Refit the retaining plate.
  • Page 104 YLINDER ASSY YLINDER ASSY AND TIMING SYSTEM AND TIMING SYSTEM EMOVING THE INTAKE MANIFOLD - Remove the flywheel cover as described in the Flywheel cover chapter. - Loosen the 3 screws and remove the intake manifold. N.B. VERSION 125 CC IS PROVIDED WITH ANTITAMPERING SCREWS.
  • Page 105 - Loosen the tightener central screw. - Remove the 2 attachments shown in the figure. - Remove the tightener with relevant gasket. - Remove the inside hexagon screw and the balance weight shown in the figure. - Remove the camshaft control pulley and the relevant was- her.
  • Page 106 EMOVING THE CAM SHAFT EMOVING THE CAM SHAFT - Remove the 2 screws and the camshaft fixing bracket shown in the figure. - Remove the camshaft. - Remove pins and rockers by the flywheel side holes. N.B. IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKERS AND FIXING BRACKET.
  • Page 107 EMOVING THE VALVES EMOVING THE VALVES - Using the specific tool with adapter, remove half-cones, plates, springs and valves. - Remove the oil guards by the specific tool. - Remove the lower spring supports. CAUTION PLACE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.
  • Page 108 NSPECTING THE SMALL END NSPECTING THE SMALL END - Using a micrometer, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEA- TING, PROCEED TO REPLACE THE DRIVING SHAFT. Characteristic Checking the connecting rod small end: Maximum diameter 15.030mm...
  • Page 109 - Using appropriate feeler gauges, measure the clearance between piston rings and grooves, as shown in the figure. - If such clearances exceed the limits given in the table be- low, replace the piston. N.B. THE HOUSINGS OF THE PIN HAVE TWO LUBRICATION CHAN- NELS.
  • Page 110 - Take the measurement 5 mm from the base in the position shown in the figure. - Carefully clean the sealing ring housings. - Using suitable probes, measure the coupling clearance between sealing rings and piston housings, as shown in the figure.
  • Page 111 NSPECTING THE CYLINDER NSPECTING THE CYLINDER Version 250 - Using a bore gauge, measure the internal diameter of the cylinder following the directions given in the figure and at three different heights. - Check that the plane of coupling with the head does not show wear or deformations.
  • Page 112 NSPECTING THE PISTON RINGS NSPECTING THE PISTON RINGS Version 125 Seal rings - Insert each of the three piston rings in turn, inside the cylin- der where it still maintains its original diameter, making sure they are perpendicular to the cylinder axis. - Measure the piston ring gap (see figure) using feeler gau- ges.
  • Page 113 N.B. BEFORE REPLACING THE LININGS, MAKE SURE THAT THE PRES- CRIPTIONS RELATING TO THE SEALING RING - HOUSINGS AND PISTON - CYLINDER COUPLING CLEARANCES ARE RES- PECTED. IN ANY CASE, NEW SEALING RINGS COUPLED WITH A SECOND-HAND CYLINDER MAY REQUIRE ADJUSTMENT CONDITIONS DIFFERENT FROM STANDARD ONES.
  • Page 114 HOOSING THE GASKET Characteristic Compression ratio - 125cc version Re: 11,50 ÷ 13:1 The length «A» to be measured refers to the piston protrusion. It indicates the amount by which the surface formed by the piston crown tops the surface formed by the upper part of the cylinder. The more the piston descends into the cylinder, the less the base gasket to be applied (to recover the compression ratio) will be and vice versa.
  • Page 115 Characteristic Compression ratio - 125cc version Re: 11,50 ÷ 13:1 The length «A» to be measured refers to the piston protrusion. It indicates me amount by which the surface formed by the piston crown tops the surface formed by the upper part of the cylinder. The more the piston descends into the cylinder, the less the base gasket to be applied (to recover the compression ratio) will be and vice versa.
  • Page 116 OMPRESSION RATIO VERSION Characteristic Compression ratio version 250 Rc: 10,5 ÷ 11,5 NOTE MOUNT ACCORDING TO THE MEASUREMENT (A) OBTAINED NOTE MEASUREMENT (A) MUST BE TAKEN WITHOUT TRIM MOUNTED BETWEEN THE CASING AND THE CYLINDER, AFTER HAVING PUT THE COMPARATOR TO ZERO, WITH ITS SUPPORT, ON A FLAT PLANE.
  • Page 117 EFITTING THE PISTON RINGS EFITTING THE PISTON RINGS Sealing ring assembly - Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening opposed to the spring junction and with the writing “top” facing upwards. In any case, the chamfering must be arranged towards the piston top.
  • Page 118 NSPECTING THE CYLINDER HEAD NSPECTING THE CYLINDER HEAD - Using a rectified bar and a thickness gauge, check that the head surface exhibits no deformations or wear. - Check that the camshaft and the rocker pin capacities ex- hibit no wear. - Check that the head cover, the exhaust manifold and the intake manifold surface exhibits no wear.
  • Page 119 NSPECTING THE VALVE SEALINGS NSPECTING THE VALVE SEALINGS - Insert the valves into the head. - Alternately test the intake and exhaust valves. - The test should be carried out by filling the manifold with fuel and checking that the head does not bleed from the valves, when pressed by your fingers only.
  • Page 120 NSPECTING THE VALVES NSPECTING THE VALVES - Check the valve stem diameter at the three points shown in the figure. - Calculate the clearance between valve and valve guide. - Check that the contact surface with the articulated register terminal is free from wear. - If the checks above give no failures, you can use the same valves.
  • Page 121 - Measure the sealing surface width on the valves and valve seats. Sealing surface width: after use: Intake and exhaust: 1.6 mm - If the valve sealing surface is wider than the prescribed limit, interrupted in one or more points, or it is bent, replace the valve.
  • Page 122 N.B. DO NOT CHANGE THE VALVE ASSEMBLY POSITION. FIT THE VALVES WITH THE REFERENCE COLOUR ON THE HALF-CO- NES SIDE (LARGER STEP CURLS). Specific tooling 020306Y Valve sealing ring drift 020382Y Tool for removing valve cotters equipped with part 012 020382Y011 Bushing (valve remover) NSPECTING THE CAM SHAFT - Check that the camshaft ends exhibit no abnormal wear.
  • Page 123 Camshaft check: Standard height Exhaust: 29,209 mm Camshaft check: Standard height Intake: 30,285 mm Camshaft check: Minimum admissible diameter Connection B Ø: 19,950mm Camshaft check: Minimum admissible diameter Connection A Ø: 36,94 mm Camshaft check: Standard diameter Connection B Ø: 19,959÷19,98 mm Camshaft check: Standard diameter Connection A Ø: 36,95÷36,975 mm IFFITING THE TIMING SYSTEM COMPONENTS...
  • Page 124 -Fit the timing chain drive sprocket onto the crankshaft with the bevelled edge towards the inserting side. - Fit the timing drive chain onto the crankshaft. - Fit the tensioning roller from the cylinder head side. - Fit the spacer with the securing bolt. - Lock the bolt at the prescribed torque.
  • Page 125 - Insert the spring with the central screw and the washer and tighten the cap at the prescribed torque - Adjust the valve clearance - Install the spark plug. Electrode distance: 0,8 mm N.B. LUBRICATE WITH GREASE THE TRAVEL END RING TO PRE- VENT ACCIDENTAL LEAKS WITH CONSEQUENT DROPPING INTO THE ENGINE.
  • Page 126 Version 250 - Insert the timing chain guide sliding block. - Insert the centring dowels between head and cylinder, ins- tall the head gasket and the head on the cylinder. Lubricate the stud bolt threading - Tighten the nuts to the first pre-torque of 7±1 N-m - Tighten the nuts to the second pre-torque of 10±1 N-m - Make a 270°...
  • Page 127 - Install pins and rockers. - Lubricate the 2 rockers through the top holes. - Lubricate the 2 connections and insert the camshaft into the head with the cams opposite the rockers. - Insert the retain plate and tighten the 2 screws shown in the figure at the prescribed torque.
  • Page 128 Install the containment bell using the balance weight fixing screw as a reference. - Tighten the central fixing screw at the prescribed torque. Locking torques (N*m) Containment bell screw 11 ÷ 15 Nm Set the tightener cursor to the rest position. - Install the tightener on the cylinder using a new gasket and tighten the 2 screws at the prescribed torque.
  • Page 129 EFITTING THE TIMING SYSTEM COMPONENTS EFITTING THE TIMING SYSTEM COMPONENTS NAME TORQUE IN Nm Tappet cover screws 6÷7 Nm Spark plug 12÷14 Nm 5÷6 Nm Tightener cap Tightener screws 11÷13 Nm Containment bell screw 11÷15 Nm Balance weight screw 7÷8,5Nm Plate screws 4÷6 Nm Sliding block screw...
  • Page 130 RANKCASE RANKCASE CRANKSHAFT CRANKSHAFT SPLITTING THE CRANKCASE HALVES Version 125 Remove the following assemblies: transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil guards as described in the Transmission chapter. - Remove the oil sump, the by-pass, the chain compartment cover, the oil pump as described in the Lubrication chapter.
  • Page 131 - Remove the crankcase gasket. - Remove the two screws and the internal cover shown in the diagram. CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT, CHECK THAT THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE BENCH BRASSES. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE BENCH BRASSES.
  • Page 132 If the driving shaft - crankcase axial clearance is higher than the standard value and the driving shaft exhibits no irregula- rity, the problem is caused by wear or by a wrong machining on the engine crankcase - Check the diameters of both half-shafts on the axes and planes shown in the figure.
  • Page 133 - Check the axial clearance of the connecting rod. - Check the radial clearance of the connecting rod. - Check that the axial clearance containment surfaces do not show scoring and using a gauge, check the width of the driving shaft as shown in the figure. - If the driving shaft-case axial clearance is greater than the standard and the driving shaft does not show any abnorma- lity, the problem is surely due to wear or incorrect machining...
  • Page 134 Characteristic Driving shaft - case axial clearance: Standard clearance 0,15 ÷ 0,40 mm Driving shaft - connecting rod axial clearance: Standard clearance 0,20 ÷ 0,50 mm Driving shaft - connecting rod radial clear-ance: Standard clearance 0,036 ÷ 0,054 mm Driving shaft width with complete washers standard measurements 55,67 ÷...
  • Page 135 N.B. ENCH ENDS ARE NOT RECTIFIABLE. Specific tooling 020074Y Crankshaft aligning tool Characteristic Alignment check: Max admissible displacement: 0,15mm 0,01 mm 0,01 mm 0,10 mm NSPECTING THE CRANKCASE HALVES - Before checking the crankcase, carefully clean all lubrica- tion channels and surfaces. - For the transmission side half-crankcase, especially clean the compartment and the channels of the oil pump, the by- pass duct, the bench brasses and the cooling jet on the trans-...
  • Page 136 N.B. THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A «LOW PRESSURE» HEAD LUBRI- CATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEM- PERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE BENCH BRASS AND CONNECTING ROD LUBRICATION PRESSURE.
  • Page 137 - The brass housing hole is in the only category reported below. - The standard brass diameter after driving is variable on the basis of a coupling selection. - The brass seats into the crankcases are classified into 2 cate- gories as for the driving shaft Cat.
  • Page 138 N.B. TO KEEP SUCH POSITION OF THE BRASSES ON THE CRANK- CASE, DRIVING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH HALF-CRANKCASES. N.B. DO NOT TAKE THE MEASURE ON THE HALFBEARING MAT- CHING SURFACE SINCE THE ENDS ARE RELEASED TO ALLOW DEFORMATION UPON INSERTION.
  • Page 139 - Insert the precleaner on the engine with relative plug. Lock to the prescribed torque. Locking torques (N*m) Engine crankcase inside head screws (transmission side half shaft) 4 ÷ 6 Engine crankcase coupling screws 11 ÷ 13 Filter union on crankcase 27 ÷ 33 Engine oil / net filter drainage cap 24 ÷...
  • Page 140 UBRICATION CONCEPTUAL DIAGRAMS Lubrification circuit Coperchio punterie Recupero gas motore Albero motore By-pass valve Carico olio Minimum pressure switch Oil pump Livelo olio nella coppa Cartridge filter Prefiltro a rete...
  • Page 141 IL PRESSURE CHECK - After removing the flywheel cover as explained in the Flywheel chapter, disconnect the minimum oil pressure swit- ch electric connection and remove the switch. - With engine at 1,650 rpm, and with oil at a temperature of ~90°C, check that oil pressure ranges between 0.5 -1.2 atm.
  • Page 142 - Install the base of the specific tool on the oil seal using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch. - Screw the threaded bar onto the base of the tool and ex- tract the oil seal. Specific tooling 020622Y Transmission-side oil guard punch.
  • Page 143 - Place the cover on the engine crankcase, apply the three screws with copper washers and install the cover into its seat by the three screws. - Tighten the 3 screws at the prescribed torque. CAUTION DO NOT LUBRICATE THE SURFACE KEYED ON THE ENGINE CRANKCASE.
  • Page 144 For version 125 to proceed with the assembly of new paraoil a side they fly by means of the indicated specific tool like in photo N.B. FAILURE TO USE THE SPECIFIC TOOL MAY RESULT IN THE OIL SEAL BEING DRIVEN TO AN UNSUITABLE DEPTH, WHICH WOULD CAUSE THE OIL SEAL TO MALFUNCTION.
  • Page 145 NSPECTION NSPECTION - Remove the two screws and the oil pump cover. - Remove the inside rotor retaining snap ring. - Remove the rotors and carefully wash them with gasoline and compressed air. - Reassemble the rotors with the pump body keeping the 2 references visible.
  • Page 146 EFITTING EFITTING -Check that the pump body-shaft is free from wear. - Check that the pump cover exhibits no wear or scratching. - In case of non-conforming values or presence of scratches, replace the faulty parts or the assembly. - Install the pump cover so as to allow the alignment of the holes for the crankcase fixing screws.
  • Page 147 - Remove the spring, the by-pass piston, the gasket and the centring dowels shown in the second figure. NSPECTING THE BY NSPECTING THE BY PASS VALVE PASS VALVE - Check the free length of the spring. - Check that the piston exhibits no scratches. - Ensure that it slides freely on the crankcase and that it gua- rantees a good seal.
  • Page 148 VALVE VALVE INSPECTING THE ONE-WAY VALVE - Remove the SAS valve - Temporarily install the rubber sleeve at the outlet of the SAS valve ensuring its seal - Connect the vacuum pump to the rubber sleeve as shown in the figure - Set the pump in vacuum position (VACUUM) - Slowly open the pump - Check that the unidirectional valve allows the passage of...
  • Page 149 NSPECTING THE CUT NSPECTING THE CUT OFF - Remove the SAS valve - Connect the pump in vacuum position (VACUUM) to the CUT - OFF valve vacuum inlet - Apply a vacuum of over 0.5 BAR - Check that this value is maintained over time - If the value is not maintained, proceed to replace - Using a «T»...
  • Page 150 UEL SUPPLY UEL SUPPLY REMOVING THE CARBURETTOR KEHIN - To disconnect the carburettor from the engine, it is neces- sary to move the air filter and remove the gas control trans- mission, the automatic starter connection, the clamps fixing the carburettor to the filter box and to the intake manifold, the pipe feeding air to the membrane, and the intake uni- - Extract the carburettor and turn it to remove the screw with the water union and relevant pipes.
  • Page 151 - Remove the clamp and the cap with the membrane cham- ber aeration filter. - Remove the 4 fixing screws shown in the figure and the vacuum chamber cover. WARNING DURING THE COVER REMOVAL, BE CAREFUL TO THE SUDDEN PROJECTION OF THE SPRING. Remove the vacuum valve with the membrane.
  • Page 152 Loosen the coupling by 1/8 turn and remove it, remove the spring and the vacuum valve pin. Remove the 4 screws shown in the figure. Remove the basin with the pickup pump, control and gas- ket. - Remove the sealing gasket. - Remove the pickup pump intake and delivery valves from the basin.
  • Page 153 - Suitably support the carburettor and remove the float pin by a hammer from the gas control side. - Remove the float and the pin. - Remove the maximum nozzle. Remove the maximum nozzle. Remove the emulsifier.
  • Page 154 Remove the spray nozzle. N.B. THIS OPERATION IS REQUIRED TO PREVENT LOSING THE SPRAY NOZZLE DURING THE CARBURETTOR CLEANING OPE- RATIONS. IF THE SPRAY NOZZLE IS FORCED INTO ITS SEAT, DO NOT REMOVE IT TO PREVENT DAMAGING IT. Remove the minimum nozzle. Remove the minimum flow adjustment screw and the spring.
  • Page 155 N.B. THIS OPERATION IS REQUIRED TO PREVENT LOSING THE SPRAY NOZZLE DURING THE CARBURETTOR CLEANING OPE- RATIONS. IF THE SPRAY NOZZLE IS FORCED INTO ITS SEAT, DO NOT REMOVE IT TO PREVENT DAMAGING IT. Remove the guard, the bracket and the starter by releasing the screw shown in the figure.
  • Page 156 N.B. DURING THE COVER REMOVAL, BE CAREFUL TO THE SUDDEN PROJECTION OF THE SPRING. Remove the vacuum valve with the membrane Loosen the coupling by 1/8 turn and remove it, remove the spring and the vacuum valve pin. Remove the 4 screws shown in the figure.
  • Page 157 Remove the basin with the pickup pump, control and gasket. Remove the pickup pump with ring nut, the casing, the O-Ring and the spring from the basin as shown in the figure. - Suitably support the carburettor and remove the float pin by a hammer from the gas control side.
  • Page 158 Remove the cap conveying the fuel to the starter nozzle as shown in the figure. - Remove the maximum nozzle. - Remove the emulsifier. Remove the spray nozzle. N.B. THIS OPERATION IS REQUIRED TO PREVENT LOSING THE SPRAY NOZZLE DURING THE CARBURETTOR CLEANING OPE- RATIONS.
  • Page 159 Remove the spray nozzle. - Remove the minimum flow screw with the O-Ring, washer and spring. - Remove the 2 fixing screws, the cover, the spring and the cut- off device membrane. CAUTION DO NOT REMOVE THE COMPONENTS FIXED INTO THE CAR- BURETTOR BODY, SUCH AS: FUEL FEEDING DUCT, PIN SEAT, STARTER NOZZLE, PICKUP NOZZLE AND PIT CAP, MINIMUM AND MAXIMUM AIR CALIBRATOR, THROTTLE VALVE CONTROL...
  • Page 160 EFITTING THE CARBURETTOR EFITTING THE CARBURETTOR KEHIN - Before proceeding to reassembly, carefully clean the car- burettor body using fuel and compressed air. - Be especially careful to the fuel inlet duct and the pin seat. - For the maximum circuit, check the air calibration shown in the figure.
  • Page 161 - Check that the throttle valve and the shaft exhibit no abnormal wear. - Check that the pin seat exhibits no abnormal wear. - In case of anomalies, replace the carburettor. - Check that the pickup pump rocker return spring is not slac- kened.
  • Page 162 - Check that the float exhibits no wear on the pin seat or on the plate in contact with the pin, or fuel infiltrations. - In case of anomalies, replace. - Insert the float with the pin on the fuel feeding side. N.B.
  • Page 163 - Wash and blow the flow screw. - Check that the screw is free from deformation and/or oxida- tion. - Assemble the spring on the screw. - Tighten the flow screw on the carburettor body. - The final position of the screw must be defined by the exhaust gas analysis.
  • Page 164 - Check that on the carburettor body there are 5 closing balls of the processing ducts. - Check that the matching surfaces with the basin and the mem- brane exhibit no dents. - Check that the vacuum valve seat is not deformed. - Check that the throttle valve and the shaft exhibit no abnormal wear.
  • Page 165 EVEL CHECK EVEL CHECK KEHIN - Place the carburettor tilted as shown in the figure, - Check that the reference on the float is parallel to the basin matching surface. - If the position is different, change the orientation of the metal pin control plate to obtain the position described abo- WALBRO - Check that the float matching surface is parallel to the ba-...
  • Page 166 - Remove the basin drainage screw and wash and blow the basin, be especially careful to the cleaning of the pickup pump intake and delivery valve. - Since the valves are unidirectional, carefully blow with com- pressed air in the intake valve from the basin internal side and into the pump piston seat for the delivery valve.
  • Page 167 - Check that the pickup pump control rocker is free from ab- normal wear. - Check that the rocker travel end screw protrudes by 3.2 - Check that the rocker return spring is not slackened. - Pre-assemble the spring and the rocker as shown in the figure.
  • Page 168 - Replace the spring with the pin lock. - Replace the vacuum chamber cover checking the proper positioning of the spring into the housing on the cover. - Tighten the screws at the prescribed torque. Locking torques (N*m) Vacuum chamber cover screws: XX N m - Wash and blow the ambient pressure inlet filter sponge.
  • Page 169 WALBRO - Check that the pin exhibits no wear and that the lock is in the third notch out of 3. - Check that the vacuum valve exhibits no scratches on the outside diameter. - Check that the 2 vacuum feeding hole are not clogged. N.B.
  • Page 170 NSPECTING THE AUTOMATIC CHOKE DEVICE NSPECTING THE AUTOMATIC CHOKE DEVICE - Check that the automatic starter piston exhibits no scrat- ches or oxidation. - Check that the piston slides freely into the seat. - Check that the piston sealing gasket exhibits no deforma- tions.
  • Page 171 KEHIN - Check that the automatic starter piston exhibits no scrat- ches or oxidation. - Check that the piston slides freely into the seat. - Check that the piston sealing gasket exhibits no deforma- tions. - The starter must be more or less inserted according to the ambient temperature.
  • Page 172 WALBRO - Check that the automatic starter piston exhibits no scrat- ches or oxidation. - Check that the piston slides freely into the seat. - Check that the piston sealing gasket exhibits no deforma- tions. - The starter must be more or less inserted according to the ambient temperature.
  • Page 173 Fork assembly M8x30 securing bolt R-Hydraulic system with right-hand Safety ring Guide bush Guide bush washer Seal Ring Dust guard R-Fork arm assembly M10x30 securing bolt Securing bolt washer Cap ring R-Fork cap assembly Bottom inner arm bush R-Plate stem assembly R-Hydraulic system with left-hand M10x50 securing bolt Steering washer...
  • Page 174 ISMANTLING FRONT SUSPENSION ISMANTLING FRONT SUSPENSION ATTENTION TO CARRY OUT THE PROCESS OF DISMANTLING THE FOR- KS WITHOUT REMOVING THEM FROM THE BOTTOM PLATE. TO DO SO, HOLD THE FORKS IN A BENCH VICE BY THE STEERING COLUMN, THEREBY PREVENTING THEM FROM BEING SCRATCHED.
  • Page 175 Extract the spring and the preload spacer. - Extract the oil seal dust guard together with its security circlip. - Firmly separate the bar from the fork stem. Extract the elements: - Dust guard (1). - Oil seal (2). - Washer (3). - Scraper (4).
  • Page 176 - Proceed with cleaning and degreasing all the front sus- pension components, so that they can be subsequently chec- ked. NSPECTING THE FRONT FORKS NSPECTING THE FRONT FORKS - Check the degree of wear on the suspension bar guide bush. Replace it in the event of it being damaged on over 30% of its total surface.
  • Page 177 Reassemble the assembly, paying special attention to the tig- htening of the fork stem, as well as the fitting of the oil seal, putting a little oil on its edges and inserting it with the aid of the special tool. Refill the hydraulic fluid and do not forget to insert the preload bush between the spring and the closing plug.
  • Page 178 Shock absorber Stand stop rubber 10M 150x55 Allen bolt O-ring D10 washer 10M 150x130 hexagonal bolt 10M150 nut 10M 150 hexagonal nut 10M 150x80 Allen bolt D10 washer Shock absorber right-hand support bracket 8M 125x30 bolt D8 washer 12M 175x35 Allen bolt Bush Shock absorber left-hand support bracket 8M 125x55 bolt...
  • Page 179 Front engine support 14Mx200x70 hexagonal bolt D15 flat washer 14M200 hexagonal nut Engine support separator bush Needle bush Engine rear support Engine securing bolt D10 washer 10M50 self-locking nut Engine support separator tube Needle bush Engine to engine support securing bolt D10 washer 10M150 self-locking nut Engine support Silentblock...
  • Page 180 ISMANTLING ISMANTLING 1. Place the motorcycle on a flat surface. WARNING SUPPORT THE MOTORCYCLE FIRMLY, IN SUCH A WAY THAT THERE IS NO RISK OF IT FALLING. Before proceeding with dismantling, support the machine on a block of wood placed under the chassis. 2.
  • Page 181 WING REMOVAL - Put the vehicle on the centre stand. - Suitably support the engine. - Unscrew the nut shown in the figure and pull out the pivot on the left side. - Unscrew the nut on the left side of the vehicle and remove the pivot on the opposite side.
  • Page 182 HECKING THE SWINGING ARM HECKING THE SWINGING ARM - Accurately grease the roller cages -Insert the spacers - Install the two halves with their respective bolts in the posi- tion indicated in the picture. - Install the bolt in the direction shown in the picture. - Position the frame-side swing-arm with the protrusion fa- cing the silent-block, as shown in the picture.
  • Page 183 VERHAUL VERHAUL - Remove the spring clip shown in the picture. - Suitably support the silencer mounting bracket. - Using special tool, extract bearing from its housing as shown in the picture. Specific tooling 020376Y Handle for punches 020456Y 0 24 mm adaptor - Using a heat gun, heat up the bearing housing.
  • Page 184 ENTRE ENTRE STAND STAND - Remove the two stand return springs. - Unscrew the nut shown in the figure. - Remove the pivot from the right-hand side. - Remove the stand. - After refitting the stand, tighten the nut with the prescribed torque.
  • Page 185 EAR WHEEL Front wheel Tyre Valve, tyre Bearing Bearing Front wheel axle Bush Washer Protector Cover Front brake disc Screw Screw Brake caliper Spring Screw Bleed Set of barke pads Screw...
  • Page 186 EAR WHEEL Front wheel Screw Tyre Washer Valve tyre Bearing Pipe Bearing Pipe Front wheel axle Bush Washer Protector Front brake disc Front brake disc Screw Brake caliper Brake caliper Spring Screw Bleed Set of brake pads Screw Distributor Tube connector Tube connector Tube connector Washer...
  • Page 187 ISMANTLING ISMANTLING WARNING - ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. - PLACE THE MOTORCYCLE ON A FLAT SURFACE. 1. Extract: - Front brake calliper (Bolts 1 and 2). 2. Extract: - Nut protecting cover. - Nut (left side).
  • Page 188 3. Check: - Spokes. Warps/damage => Replace. 4. Measure: - Distortion of the front wheel Above that specified => Replace. Distortion limits for the front wheel: Radial (a): 0,5 mm Lateral (b): 0,8 mm 5. Check: - Front wheel bearings. Bearings allow play in the wheel hub or the wheel does not turn freely =>...
  • Page 189 ISMANTLING THE FRONT DISK CALLIPER ISMANTLING THE FRONT DISK CALLIPER - Loosen the banjo bolt (1) from the bottom end of the brake pipe and tighten it slightly. - Unscrew the calliper mounting bolts (2) and separate the calliper (3) backwards from the disk. PRECAUTION CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA- TELY.
  • Page 190 Extracting the front brake pads. - Remove the front brake calliper (see “Dismantling the front brake calliper” in this chapter). Extract: - Pad springs (1). - Pin. - Brake pads (2). Fitting the front brake pads - Press the calliper pistons in manually. - Fit the pads inside the calliper.
  • Page 191 N.B. THE MASTER CYLINDER (1) IS INCORPORATED INTO THE FRONT BRAKE LEVER ASSEMBLY. - EXTRACT THE SCREWS (2) AND THE FRONT BRAKE LEVER ASSEMBLY. PRECAUTION CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA- TELY. Extract: - Brake lever mounting bolt and nut. - Brake lever.
  • Page 192 Checking the brake calliper main cylinder: - Check that the anti-dust boots are not damaged. If they are, change them. - Check that the piston return is not damaged. If it is, renew it. - Check that the relief port and feed port are not blocked. if the relief port is blocked, the brake pads will bind on the disk.
  • Page 193 Brake disk distortion: - Raise the motorcycle on the jack so that the tyre is clear of the ground. - To check the front disk, turn the handlebars completely to one side. - Place a dial calibrator against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is turned by hand (B).
  • Page 194 Purge the air completely from the master cylinder using this procedure. - Remove the transparent plastic cap from the bleed nipple and place the other end of the pipe in a container. - Repeat the following procedure until there is no air left emerging from the plastic pipe: - Pump the brake lever until it becomes hard and holds the brakes down.
  • Page 195 3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR USE IN THE BRAKE. THIS LOWERS THE BRAKE FLUID EVA- PORATION POINT AND MAY RESULT IN THE BRAKES NOT WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DE- TERIORATION OF THE BRAKE PARTS. 4) DO NOT LEAVE THE RESERVOIR CAP OFF AT ANY TIME, TO PREVENT CONTAMINATION OF THE FLUID.
  • Page 196 SSEMBLING THE FRONT WHEEL SSEMBLING THE FRONT WHEEL Reverse the “DISMANTLING” procedures. Take care with the following points: 1. Lubricate: - Front wheel axle. - Bearing. - Retaining rings. Recommended lubricant: Lithium soap based grease 2. Fit: - Front wheel 3.
  • Page 197 EAR WHEEL Rear rim Tyre Valve, tyre Bush Bush Brake disc bracket Screw Washer Rear brake disc Screw Bracket Screw Washer Washer Rear clip assembly Screw Washer Spring Screw Bleed Set of brake pads...
  • Page 198 EAR WHEEL Rear rim Tyre Valve, tyre Bush Bush Brake disc bracket Screw Washer Rear brake disc Screw Bracket Screw Washer Washer Rear clip assembly Screw Washer Spring Screw Bleed Set of brake pads...
  • Page 199 ISMANTLING ISMANTLING WARNING - ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING. - PLACE THE MOTORCYCLE ON A FLAT SURFACE. - Place the machine on the centre stand so that the rear wheel is slightly raised.
  • Page 200 Fitting the rear calliper - Fit the bottom end of the flexible brake pipe and the calliper. - Tighten the brake banjo bolt. - Check brake fluid level. - Bleed the braking system pipe (consult “Bleeding the brake system pipe”, in the chapter corresponding to the front brakes).
  • Page 201 WARNING DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE PEDAL IS OPERATING FULLY. PUMP THE LEVER UN- TIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKE WILL NOT WORK THE FIRST TIME THE PEDAL IS USED. Inspecting the pads for wear - Removing the rear brake pads.
  • Page 202 Checking the rear main cylinder (visual check) - Extract the main cylinder (consult “Extracting the rear main cylinder” in this section). - Dismantle the rear main cylinder. - Check that there are no scratches, corrosion or holes in the inner walls of the main cylinder and on the outer part of each piston.
  • Page 203 Brake disk wear - Measure the thickness of the disks (A) at the point where they are most worn. - If the disk is more worn than specified in the service limit, renew it. Measurement area (B). Standard brake disk thickness: 3.8 ÷...
  • Page 204 Extract: - Bolts (1). - Reservoir cap (2). - Fill the reservoir with brake fluid up to the top reservoir line. - With the cap removed, pump the brake lever slowly several times until no bubbles can be seen rising through the liquid. Purge the air completely from the master cylinder using this procedure.
  • Page 205 WARNING WHEN WORKING WITH THE DISK BRAKE, TAKE THE FO- LLOWING PRECAUTIONS: 1) NEVER RE-USE BRAKE FLUID. 2) DO NOT USE FLUID FROM A CONTAINER THAT HAS BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PRO- LONGED PERIOD OF TIME. 3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR USE IN THE BRAKE.
  • Page 206 NSPECTING THE REAR WHEEL NSPECTING THE REAR WHEEL 1. Inspect: - Rear wheel axle - Rear wheel - Rear wheel bearings - Retaining rings See the “WHEEL AND REAR BRAKE” section 2. Measure: - Distortion of the rear wheel See the “WHEEL AND REAR BRAKE” section ITTING THE REAR WHEEL ITTING THE REAR WHEEL Reverse the “DISMANTLING”...
  • Page 207 IRCUIT DIAGRAM ENGINE 250 NGINE COOLING CIRCUIT SPECIFICATION DESC. / QUANTITY Carburettor heating circuit Thermostat with by-pass Expansion tank Radiator...
  • Page 208 IRCUIT DIAGRAM ENGINE 125 NGINE COOLING CIRCUIT SPECIFICATION DESC. / QUANTITY Carburettor heating circuit Thermostat with by-pass Expansion tank Radiator...
  • Page 209 ATER PUMP ATER PUMP OVERHAUL OVERHAUL ENGINE 125 - In case of noise of the bearings or fluid leaks from the insi- de drainage hole, proceed to the water pump overhaul. - Remove the flywheel cover with the water pump from the engine (see chapter 4).
  • Page 210 - Using the thermal gun, heat the flywheel cover from the internal side. - Place the flywheel cover on the ring base in a way similar to the removal steps. - Place the pair of bearings on the specific punch. - Keep the bearings on the specific tool by grease.
  • Page 211 N.B. PERFECTLY CENTRE THE PUNCH ON THE IMPELLER. MOVE THE SHAFT AND CHECK THAT THE FLYWHEEL COVER TUR- NS IN PLANE. FAILURE TO OBSERVE THIS REGULATION CAN DAMAGE THE DRIVE. N.B. DO NOT LUBRICATE THE 0-RING. FAILURE TO OBSERVE THIS RULE CAUSES A DEFORMATION OF THE RING. Specific tooling 020440Y Water pump overhaul tool Locking torques (N*m)
  • Page 212 The pump can be services using the special tool and a press. The special tool is designed to be used with the presses most commonly found in workshops. For those presses equipped with a 35-mm piston and protective cap with fixing screw, it is sufficient to remove the cap and install the components of the special tool in its place.
  • Page 213 Remove the ceramic seal from the pump shaft. Using a screwdriver, remove the ceramic ring and sealing gasket from the flywheel cover. N.B. IN THE EVENT YOU PLAN TO REUSE THE MECHANICAL SEAL, PAY ATTENTION DURING THE DISASSEMBLY STAGES IN ORDER TO NOT CHIP THE CERAMIC RING. - Remove the joint from the seat inside the seal ring.
  • Page 214 Before you reassemble, wash all the components and conti- nue with the following checks. Flywheel cover: Check that there are no cracks or oxidation on the seat of the ceramic seal. Check the capacity loads of the bearings and of the seal ring. Check the efficiency of the drain hole.
  • Page 215 Heat the flywheel cover using the heat gun N.B. IF THE JOB IS PERFORMED WITH THE STATOR MOUNTED, HEAT FROM THE EXTERNAL SIDE OF THE COVER. Specific tooling 020151Y Air heater 020150Y Support for air heater Properly support the cover and using the modular punch, install the two bearings all the way down at the same time.
  • Page 216 Position the flywheel cover on the press using the support base for the bearings that is part of the special tool. Install the special punch with the impeller’s template on the press piston. Specific tooling 020628Y Water pump overhaul kit - quasar 250 Manually insert the pump shaft in the relative bearings.
  • Page 217 Remove the special punch from the press piston and support the flywheel cover from the impeller side with it. Put the new oil seal on the special punch while being careful to position the seal lip starting from the side of the handle. Install the oil seal on the flywheel cover all the way to the depth determined by the punch.
  • Page 218 Lubricate the oil seal with motor oil.
  • Page 219 GP1 125-250 5 50 LECTRICAL SYSTEM O - Orange GR - Green B - Black BR - Brown W - White G - Gray Y - Yellow BL - Blue R - Red P - Pink VI - Violet SBL- Sky blue Starter motor Headlamp assembly Temperature thermoresistenace...
  • Page 220 HECKING CONNECTORS HECKING CONNECTORS Check for corrosion, damp etc. in the connectors. 1. Disconnect: - Connectors 2. Dry each of the terminals with compressed air. 3. Connect and disconnect two or three times. 4. Pull the conductor to check if it is loose. 5.
  • Page 221 NSPECTION STEPS NSPECTION STEPS Using a multimeter, check the circuit between the terminals to make sure that they are correctly connected. Replace the component if any of the combinations gives an incorrect rea- ding. N.B. - SWITCH THE “ON” AND “OFF” SWITCH ON AND OFF SEVERAL TIMES.
  • Page 222 GNITION Voltage regulator. Battery 15A fuse CDIU Digital instruments unit Fan thermostat switch Hall sensor Oil pressure sensor Petrol reserve sensor Temperature thermo-resistance Engine stop switch...
  • Page 223 IGHTS AND AUTOMATIC CHOKE Alternator Voltage regulator Automatic choke Rear light Digital instruments unit Front sidelight bulbs Dipped headlight bulbs Main beam headlight bulbs Pick-Up Ignition key switch Light switch 15A fuse Battery CDIU...
  • Page 224 ECHARGING THE BATTERY AND STARTING Alternator Voltage regulator 15A fuse Battery Starter relay Starter motor Starter switch STOP button Engine stop Switch CDIU...
  • Page 225 ENSORS AND INDICATORS Voltage regulator Battery 15A fuse CDIU Digital instruments unit Fan thermostat switch Hall sensor Oil pressure sensor Petrol reserve sensor Temperature thermo-resistance Engine stop Switch...
  • Page 226 URN INDICATORS AND HORN CDIU Battery 15A fuse Switch Digital instruments unit Horn Horn button Turn indicator bulbs Turn indicator button Diode box Engine stop Switch...
  • Page 227 GNITION CIRCUIT GNITION CIRCUIT Ignition system Once the ¡mmobilizer system has been enabled, it is possible to have the spark at the spark plug by the H.V. coil and the signáis coming from the Pick-Up. The basic power supply comes from the battery, the system is calibrated in such a way that any drops of voltage of the bat- tery are perceived by the start up system but are unimportant for the start up system.
  • Page 228 - H.T. coil secondary circuit check Disconnect the spark plug cap from the H.T. cable and mea- sure the resistance between the end of the H.T. cable and the negative terminal of the H.T. coil (see figure). If the measured values are not as specified, replace the H.T. coil.
  • Page 229 TATOR CHECK TATOR CHECK Disconnect the connector from the voltage regulator and check the presence of continuity between each yellow wire with the other two. Electric characteristic Stator check 1 Ohm value: 0,7 ÷ 0,9 Ohm Also check that each yellow wire is insulated from earth. If non-conforming values are detected, repeat the checks di- rectly on the stator;...
  • Page 230 ECHARGE SYSTEM VOLTAGE CHECK ECHARGE SYSTEM VOLTAGE CHECK The battery recharge system consists of a threephase gene- rator and a permanent-magnet flywheel. The generator is directly connected to the voltage regulator. The latter is in turn directly connected to earth and to the battery positive terminal via the 15A protection fuse (no.
  • Page 231 USES USES The electrical system is protected by a fuse located on the r.h.s. of the battery bay. To replace it, lift the seat, remove the battery access door and then the transparent fuse cover. Ignition system, headlight, and taillight are not protected by the fuses.
  • Page 232 - Upturn the electrolyte container with the six closing surfa- ces aligned with the six battery filling holes. - Push the container down with enough force to break the seals. The electrolyte should then begin to flow into the bat- tery.
  • Page 233 ATTERY INITIAL CHARGE Accepting that a battery requiring no maintenance can be used only once it has been filled with electrolyte, the battery may be incapable of starting the engine in the cases indica- ted in the following table, where it is necessary firstly to give it an initial charge.
  • Page 234 TAKE CARE KEEP THE BATTERY AWAY FROM SPARKS OR NAKED FLA- MES DURING THE CHARGING PROCESS, SINCE THE BAT- TERY GIVES OFF AN EXPLOSIVE MIXTURE OF HYDROGEN AND OXYGEN GASES. WHEN USING A BATTERY CHARGER, CONNECT THE CHARGER TO THE BATTERY BEFORE PLU- GGING IT IN.
  • Page 235 N.B. CARRY OUT THE MEASUREMENT WITH A DIGITAL VOLT- METER (A) THAT CAN READ VOLTAGES WITH DECIMAL FI- GURES. * IF THE READING IS BELOW THAT SPECIFIED, THE BATTERY NEEDS TO BE RECHARGED. Battery terminal voltage Standard: 12.5v or higher - Measure the voltage at the battery terminals.
  • Page 237 ENGINE OOR PERFORMANCE POSSIBLE CAUSE WORK Dirty-carburettor; feeding pump or vacuum Remove, wash with solvent, dry with compressed cock failure air or replace. Excessive scaling in the explosion chamber Remove the scale from cylinder, piston, head and valves. Wrong timing or worn timing components Restore the timing or replace worn parts.
  • Page 238 EAR WHEEL TURNING WITH IDLE ENGINE POSSIBLE CAUSE WORK Idle rpm too high Adjust the engine idle speed and the CO%, if requi- red. Clutch failure Check clutch springs / masses TARTING DIFFICULTIES POSSIBLE CAUSE WORK Altered fuel characteristics Drain altered fuel and refuel. Start up speed too low or starter system and Check the starter motor, the system and the torque motor failure...
  • Page 239 TARTING DIFFICULTIES POSSIBLE CAUSE WORK Defective float valve Check the proper sliding of the float and the valve efficiency Carburettor nozzles clogged Remove, wash with solvent, dry with compressed air XCESSIVE OIL CONSUMPTION SMOKE UPON EXHAUST POSSIBLE CAUSE WORK Worn valve guides Check and replace the head unit if required Worn valve oil guard Replace the valve oil guard...
  • Page 240 ENGINE TENDS TO CUT-OFF AT FULL THROTTLE HE ENGINE TENDS TO STOP AT MAX GAS OPENING POSSIBLE CAUSE WORK Defective feeding circuit Check the feeding pump, the vacuum inlet, and the duct seal, replace if required. Incorrect float level Restore the level in the basin by bending The fuel inlet pin thrusting reed on the float so as to have the float parallel to the basin plane with upturned carburettor.
  • Page 241 HIGH FUEL CONSUMPTION IGH CONSUMPTION POSSIBLE CAUSE WORK Float level Restore the level in the basin by bending the fuel inlet pin thrusting reed on the float so as to have the float parallel to the basin plane with upturned carburettor. Slackened nozzles Check the maximum and minimum nozzle locking into their seat...
  • Page 242 SAS MALFUNCTIONS ECONDARY AIR DEVICE ANOMALIES POSSIBLE CAUSE WORK Cutoff valve of the secondary air device not Replace the secondary air device working Vacuum inlet pipe from the secondary air Replace the pipe device disconnected or cracked Reed valve of the secondary air device does Replace device and sleeve.
  • Page 243: Electrical System

    RAKES OVERHEATING POSSIBLE CAUSE WORK Rubber gaskets expanded or sealed Replace the gaskets. Pump compensation holes clogged Clean carefully and blow with compressed air. Brake disc slackened or deformed Check the tightening of the brake disc screws; measure the disc axial deviation using a comparator and keeping the wheel mounted on the vehicle.
  • Page 244 TURN SIGNAL LIGHTS MALFUNCTION LASHING LIGHTS NOT WORKING POSSIBLE CAUSE WORK Electronic ignition device failure. With the key switch set to «ON» connect the jumpers 1 (Blue-Black) and 5 (Red/Blue) on the control unit con- nector. If lights do not turn on and remain solid when the flashing light control is actuated, replace the con- trol unit, otherwise check the wiring and the switch.
  • Page 245 OISY SUSPENSION POSSIBLE CAUSE WORK Noisy suspension If the front suspension is noisy, check: the front shock absorber efficacy, the condition of the ball bearings and the relevant locking nuts; the travel end rubber pads and the sliding bushes. Finally, check the tighte- ning torques of the wheel hub, brake caliper, disc and shock absorber in the connection to the hub and to the steering tube.

This manual is also suitable for:

Gp1 125 c.c.Gp1 250 c.c.

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