PIAGGIO NRG Power DT Workshop Manual
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PIAGGIO NRG Power DT Workshop Manual

Nrg power dt 633257
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WORKSHOP MANUAL
633257
NRG Power DT

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Summary of Contents for PIAGGIO NRG Power DT

  • Page 1 WORKSHOP MANUAL 633257 NRG Power DT...
  • Page 2 Not all versions shown in this publication are available in all Countries. The availability of individual versions should be confirmed with the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 WORKSHOP MANUAL NRG Power DT This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
  • Page 9 NRG Power DT Characteristics Vehicle identification Frame prefix: ZAPC45300 ÷ 1001 Engine prefix: C453M Dimensions and mass DIMENSIONS AND MASS Specification Desc./Quantity Max length 1790 mm. Max width 850 mm. Seat height 795 mm. Wheelbase 1280 mm Dry weight 95 kg.
  • Page 10 NRG Power DT Characteristics Engine ENGINE Specification Desc./Quantity Engine type Two-stroke, single cylinder Piaggio Hi-PER2 Bore x stroke 40 X 39.3 mm Cubic capacity 49.40 cc Compression ratio 9.4 to 10.4 :1 Carburettor DELL'ORTO PHVA 17.5 CO adjustment 3.5% ± 0.5 Engine idle speed 1800 to 2000 r.p.m.

  • Page 11: Electrical System

    NRG Power DT Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator, torque server, V belt, automatic clutch, gear reduction unit. Capacities CAPACITY Specification Desc./Quantity Rear hub oil Quantity : ~ 85 cc Mixer oil 1.2 litres Fuel tank capacity 6.5 litres (1.5 litres of reserve)

  • Page 12: Wheels And Tyres

    NRG Power DT Characteristics Specification Desc./Quantity Rear brake (Ø 110 mm) drum brake with expanding shoes, mechanically controlled (lever on the handlebar left hand end). Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front tyre Tubeless 120/70-13" Rear tyre Tubeless 140/60 x 13'' Wheels With circles of 3.50 x 13"...

  • Page 13: Tightening Torques

    NRG Power DT Characteristics Dell'Orto DELL'ORTO CARBURETTOR Specification Desc./Quantity Type PHVA 17.5 RD Diffuser diameter Ø 17.5 Adjustments reference number 8440 Maximum nozzle: Maximum air nozzle (on the body): Ø 1.5 Tapered pin stamped code: Pin position (notches from above):...

  • Page 14: Assembly Clearances

    NRG Power DT Characteristics Name Torque in Nm Brake pump support fixing screw 7 to 10 Nm Brake fluid pump - hose fitting 13 to 18 Nm Brake fluid tube - calliper fitting 20 to 25 Nm Calliper tightening screw...
  • Page 15 NRG Power DT Characteristics Name Initials Cylinder Piston Play on fitting coupling 1st over- 40.212 - 40.219 40.15 - 40.157 0.055 - 0.069 size coupling 1st over- 40.219 - 40.226 40.157 - 40.164 0.055 - 0.069 size coupling 1st over- 40.226 - 40.233...
  • Page 16 NRG Power DT Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Connecting rod 11.750-0.05 clearance E = 0.25 to 0.50 shoulder washer 0.5 ± 0.03 clearance E = 0.25 to 0.50 - clearance...
  • Page 17 NRG Power DT Characteristics HIMMING SYSTEM Name Measure A Thickness Shimming 2.80 ÷ 3.04 Shimming 3.04 ÷ 3.24 Shimming 3.25 ÷ 3.48 Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the...
  • Page 18 NRG Power DT Characteristics CHAR - 12...
  • Page 19 INDEX OF TOPICS TOOL OOLING...
  • Page 20 NRG Power DT Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15-mm bear-...
  • Page 21 NRG Power DT Tooling Stores code Description 001467Y017 Bell for bearings, outside Ø 39 001467Y021 Extraction pliers for ø 11 mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels...
  • Page 22 NRG Power DT Tooling Stores code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Start-up crown lock 020166Y Pin lock fitting tool TOOL - 4...
  • Page 23 NRG Power DT Tooling Stores code Description 020261Y Starter spring fitting 020262Y Crankcase splitting strip 020265Y Bearing fitting base 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol TOOL - 5...
  • Page 24 NRG Power DT Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge TOOL - 6...
  • Page 25 NRG Power DT Tooling Stores code Description 020350Y Electrical system check instru- ment 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide 020456Y Ø 24 mm adaptor TOOL - 7...
  • Page 26 NRG Power DT Tooling Stores code Description 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 020625Y Kit for sampling gas from the ex- haust manifold 494929Y Exhaust fumes analyser TOOL - 8...
  • Page 27 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 28: Maintenance Chart

    NRG Power DT Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change AFTER 1000 KM Action Hub oil - change Oil mixer/throttle linkage - adjustment Odometer cable - greasing Steering - adjustment Brake control levers - greasing Brake fluid level - check...
  • Page 29 NRG Power DT Maintenance Action Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle and brake test - road test (*) See regulations in the «Adjusting the idle speed» section...
  • Page 30 NRG Power DT Maintenance Action Hub oil - change Spark plug/electrode gap - replacement Air filter - clean Idling speed (*) - adjustment Oil mixer/throttle linkage - adjustment Driving belt - replacement Variable speed rollers - replacement Odometer cable - greasing...

  • Page 31: Checking The Spark Advance

    NRG Power DT Maintenance Checking the spark advance -Check to be made at over 4000 rpm with strobo- scopic gun. The advanced ignition measured must be 17° before the TDC. - This value is correct when the reference mark on...
  • Page 32 NRG Power DT Maintenance - Refit the central flap. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MOTOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERI- OUSLY DAMAGE THE ENGINE.

  • Page 33: Air Filter

    NRG Power DT Maintenance Replacement - Remove oil filler cap «A». - Loosen oil draining cap «B» and allow for the system to drain completely. - Refit the draining cap and refill the hub with the prescribed oil. Characteristic Rear hub oil...

  • Page 34: Checking The Ignition Timing

    NRG Power DT Maintenance Checking the ignition timing - Adjust the control cables: Mix cable: see procedure indicated in "Mixer tim- ing". Throttle cable: adjust the set screw on the carbu- rettor in such a way that the sheath has no back- lash.

  • Page 35: Braking System

    NRG Power DT Maintenance Braking system Level check Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal; - Check the level of liquid with the related warning light «A». A certain lowering of the level is caused by wear on the pads.

  • Page 36: Headlight Adjustment

    NRG Power DT Maintenance ID AND THE BLEEDING OF AIR FROM THE CIRCUITS. Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the...
  • Page 37 NRG Power DT Maintenance Attach the exhaust gas collection tube to the sec- ondary air rubber manifold. Such joint must be sealed in order to guarantee accurate CO read- ings. - Start the engine, adjust the idle speed to 1,700 ± 100 rpm and check the CO value is equal 3.5 ± 1% - If the parameters found do not agree with the above figures, act upon the idle adjusting screw.
  • Page 38 NRG Power DT Maintenance − Ensure the one-way valve packing properly seals the aluminium outlet fitting. − Refit the aluminium outlet onto the SAS box as shown in the picture. - Attach the special tool and move the joints as shown in the figure.
  • Page 39 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 40: Rear Wheel Spins At Idle

    NRG Power DT Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Defective fuel pump or damaged depression line...
  • Page 41 NRG Power DT Troubleshooting Possible Cause Operation Starter inefficient Check: electric wiring, circuit continuity, mechani- cal sliding and power supply Battery flat Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into...
  • Page 42 NRG Power DT Troubleshooting Engine tends to cut-off at idle ENGINE STOP IDLING Possible Cause Operation Minimum nozzle dirty Wash the nozzle with solvent and dry with com- pressed air Starter that stays open Check: electric wiring, circuit continuity, mechani-...
  • Page 43 NRG Power DT Troubleshooting Clutch grabbing or performing inadequately CLUTCH Possible Cause Operation Tear or irregular functioning Check that the masses open and return normally Check that there is no grease on the masses Check that the clutch masses' contact surface with...

  • Page 44: Rear Wheel

    NRG Power DT Troubleshooting Battery BATTERY Possible Cause Operation Battery The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically.

  • Page 45: Noisy Suspension

    NRG Power DT Troubleshooting Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation EXCESSIVE STEERING CLEARANCE Check the tightening of the top and bottom ring nuts. If irregularities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace if they are recessed.
  • Page 46 NRG Power DT Troubleshooting TROUBL - 8...
  • Page 47 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 48 NRG Power DT Electrical system LEGEND Specification Desc./Quantity Voltage regulator Horn button Turn signal switch Light switch Rear brake stop button Front L.H. turn signal light Front headlight Two rear parking light bulbs 12V - 3W Horn Light bulb 12V - 35W for high-beam lamp Light bulb 12V - 35W for low-beam lamp Front R.H.
  • Page 49 NRG Power DT Electrical system Specification Desc./Quantity Mixture oil warning light switch Starter remote control Magneto flywheel Control device ignition Automatic starter Starter motor Taillight resistor Rear R.H. turn signal light Taillight assembly Choke device continuity check light Battery 12V - 4Ah Rear L.H.
  • Page 50 NRG Power DT Electrical system Specification Desc./Quantity Pick - up Key switch Spark plug Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity Flywheel magneto Voltage regulator Automatic starter LED taillight Digital instrument unit Headlamp sidelight bulbs...
  • Page 51 NRG Power DT Electrical system Battery recharge and starting BATTERY RECHARGE AND STARTING Specification Desc./Quantity Flywheel magneto Voltage regulator Fuse 7,5A Battery 12V-14Ah Starter remote control Starter motor LED taillight Ignition key-switch Start up button Stoplight switches Mixture oil level sender...
  • Page 52 NRG Power DT Electrical system Level indicators and enable signals section SAFETY SWITCHES AND LEVEL GAUGES Specification Desc./Quantity Voltage regulator Ignition key-switch Fuse 7,5A Battery 12V-14Ah Starter button Starter remote control Starter motor Stoplight switches Fuel level sender Coolant temperature sensor...

  • Page 53: Turn Signal Lights

    NRG Power DT Electrical system Turn signal lights TURN SIGNALS AND HORN Specification Desc./Quantity Voltage regulator Ignition key-switch Fuse 7,5A Battery 12V-14Ah Horn button Horn Turn signal lights Turn signal switch Digital instrument unit Digital instrument panel DASHBOARD CONNECTOR Specification Desc./Quantity...
  • Page 54 NRG Power DT Electrical system Specification Desc./Quantity + Right direction indicator + Left direction indicator Low-oil warning light Low-fuel warning light Not connected Not connected Not connected Checks and inspections Checks to be made in the case of ignition ir- regularities and/or no spark on the spark plug 1.
  • Page 55 NRG Power DT Electrical system 020331Y Digital multimeter CHECKING THE RECHARGE COIL Specification Desc./Quantity White/green cable 800±1100 ohm CHECK CONTINUITY Specification Desc./Quantity White cable-frame continuity White cable-engine continuity Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the con-...
  • Page 56 NRG Power DT Electrical system 4. Battery not recharging. 5. Turn signals not operational. 6. Dashboard check not operational. Interventions FAULT 1 Replace the regulator as definitely faulty. FAULT 2 a) Check the output from the stator gives the cor-...
  • Page 57 NRG Power DT Electrical system FAULT 4 a) Interposing the AC tester between the black and yellow cables on the regulator, check the genera- tor output voltage is within the prescribed values (this measurement must be carried out with the battery detached).
  • Page 58 NRG Power DT Electrical system is found, check wiring and terminals on key-switch and battery. • Repeat the same procedure with the ends of the tester inserted between contact 5 (+) and 6 (-) and check the presence of the battery voltage with the key switch at on.
  • Page 59 NRG Power DT Electrical system 020331Y Digital multimeter Fuses The electrical system is protected by a fuse loca- ted 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 60 NRG Power DT Electrical system IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CON- TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF. Dry-charge battery WARNING THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON- TAINS SULPHURIC ACID.
  • Page 61 NRG Power DT Electrical system 1 Hold the vertical tube 2 Look at the level 3 The float must be freed Battery maintenance The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are: 1) Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level.
  • Page 62 NRG Power DT Electrical system NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE. CAUTION ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY.
  • Page 63 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 64 NRG Power DT Engine from vehicle Removal of the engine from the vehicle 1. Detach the battery. 2. Remove the exhaust assy. 3. Remove the rear wheel. 4. Remove the rear brake cable. 5. Detach the electrical connection to the fly- wheel.
  • Page 65 INDEX OF TOPICS NGINE...

  • Page 66: Automatic Transmission

    NRG Power DT Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.
  • Page 67 NRG Power DT Engine Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 - Remove the screws shown in the figure and re- move the engine starting lever. - For the assembly, work in reverse and tighten the screws to the prescribed torque..

  • Page 68: Inspecting The Clutch Drum

    NRG Power DT 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 69 NRG Power DT 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...
  • Page 70 NRG Power DT 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...
  • Page 71 NRG Power DT Engine Inspecting the driven fixed half-pulley - Check that there are no signs of wear on the work surface of the belt. If there are, replace the half- pulley.. - Make sure the bearings do not show signs of un- usual wear.
  • Page 72 NRG Power DT Engine - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole.

  • Page 73: Refitting The Driven Pulley

    NRG Power DT Engine Refitting the clutch - Preassemble the driven pulley group with spring, sheath and clutch. - Position the spring with the sheath - Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar.

  • Page 74: Removing The Driving Pulley

    NRG Power DT Engine Drive-belt - Make sure the driving belt is not damaged and does not have cracks in the toothed grooves. - Check the width of the belt. Characteristic Transmission belt/Minimum width 17.5 mm Removing the driving pulley - Lock the driving pulley using the appropriate tool.
  • Page 75 NRG Power DT 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 76 NRG Power DT Engine Refitting the driving pulley - Manually move the mobile driven half-pulley away pulling it towards the clutch unit and insert the belt repeating the direction of rotation of the first fitting. N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE...
  • Page 77 NRG Power DT Engine Removing the hub cover • Remove the transmission cover • Remove the clutch assembly • Discharge the rear hub oil. • Remove the 5 screws indicated in the figure. • Remove the hub cover with driven pulley shaft.
  • Page 78 NRG Power DT Engine Removing the driven pulley shaft bearing - Remove the seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane. - Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.
  • Page 79 NRG Power DT Engine Inspecting the hub cover - Check that the fitting surface is not dented or dis- torted. - If faults are found, replace the hub cover. Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the...
  • Page 80 NRG Power DT Engine 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 81 NRG Power DT Engine Locking torque: 11 to 13 Nm Flywheel cover Cooling hood - Remove the four fixings shown in the figure. - Remove the fan cover - Remove the oil piping retention band from the hood - Remove the 2 screws shown in the figure...

  • Page 82: Removing The Stator

    NRG Power DT Engine Cooling fan - Remove the cooling fan by acting on the three fixings indicated in the figure. Removing the stator - Remove the three stator fixings shown in the photo - Remove the two pick-up fixings shown in the...
  • Page 83 NRG Power DT Engine Removing the starter motor • Remove the center stand by unscrew- ing the four clamping screws (two per side) of the engine block • emove the two clamps shown in the figure Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner.
  • Page 84 NRG Power DT Engine Inspecting the flywheel components - Check the condition of the flywheel and any dis- tortions that might cause rubbing on the stator and on the Pick-Up. Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly.
  • Page 85 NRG Power DT Engine Cylinder assy. and timing system Removing the intake manifold Use an anti-tampering TORX spanner to remove the two clamping screws of the intake manifold Removing the cylinder head Remove the 4 screws shown in the figure Removing the cylinder - piston assy.

  • Page 86: Inspecting The Small End

    NRG Power DT Engine Remove the snap rings and remove the pin CAUTION AFTER EACH REMOVAL OPERATION RE- PLACE THE PIN RETENTION SNAP RINGS Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer.

  • Page 87: Inspecting The Piston

    NRG Power DT Engine Inspecting the piston - Measure the bearings on the piston using a bore meter - Calculate the piston-pin coupling clearance. Characteristic Wrist pin housing: standard diameter 12 +0.007 +0.012 Wrist pin housing: standard clearance 0.002 ÷ 0.011 mm - Measure the outer diameter of the piston, per- pendicular to the pin axis.

  • Page 88: Removing The Piston

    NRG Power DT Engine Inspecting the piston rings - Alternatively insert the two sealing rings in the cylinder Using the piston, insert the seals perpendicularly to the cylinder axis. - Measure the opening of the sealing rings using a thickness gauge as shown in the photograph...
  • Page 89 NRG Power DT Engine Inspecting the timing system components CAUTION CHECK THE CORRECT REED UNIT SEAL; NO LIGHT MUST PASS BETWEEN THE SUPPORT AND LAMELLA. Crankcase - crankshaft ENG - 25...
  • Page 90 NRG Power DT Engine Splitting the crankcase halves Remove the eight crankcase union fasteners. Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling...
  • Page 91 NRG Power DT Engine Removing the crankshaft bearings The bearings can stay on either the half crankcase or the crankshaft indifferently - Using the special tool, remove any bearings that have been left on the crankshaft N.B. The half rings must be inserted on the bearings with a few mallet blows.
  • Page 92 NRG Power DT Engine Inspecting the crankshaft alignment With the specific tool shown check that the eccen- tricity of the surfaces of diam. «A»-«B»-« C» are within 0.03 mm. (reading limit on the dial gauge); in addition, check the eccentricity of diam. «D», for which a maximum reading of 0.02 mm is permitted.
  • Page 93 NRG Power DT Engine - Let the temperature of the half crankcase settle at the temperature of the crankshaft. - Again install the special crankcase separation plate NOT installing the crankshaft protection - During the assembly phase keep the central thrust screw loose.
  • Page 94 NRG Power DT Engine - Move the crankcase separation plate in a position back from the one indicated in the figure - Install the special magnetic support with dial gauge at the end of the crankshaft - Check the axial clearance of the crankcase...

  • Page 95: Oil Pump

    NRG Power DT Engine - Install a new transmission side oil seal using the special tool with adapter ring. The transmission-side oil seal is recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump...

  • Page 96: Fuel Supply

    NRG Power DT Engine Refitting To refit, perform the steps in the reverse direction to disassembly Remember to drain after refitting using the screw shown in the figure Fuel supply The vehicle comes with a membrane pump con- trolled by the depression that is generated in the intake manifold.
  • Page 97 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 98: Removing The Front Wheel

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

  • Page 99: Front Fork

    NRG Power DT Suspensions Refitting When refitting, tighten to the prescribed torque and apply the recommended grease to the threaded cone. Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 °...
  • Page 100 NRG Power DT Suspensions - Remove the wheel axle. - Remove the screw (4). - Remove the stanchion (3). - Remove the dust guard (1). - Insert the new sealing ring after lubricating the inside parts of the ring and paying attention not to damage it.

  • Page 101: Steering Column

    NRG Power DT Suspensions operations mentioned above and replace the shock absorber-stem unit. When refitting, tighten to the prescribed torque and apply the recommended grease to the threadlock nut. Specific tooling 020150Y Air heater support 020151Y Air heater Recommended products...
  • Page 102 NRG Power DT Suspensions - Only remove the seats if it is strictly necessary. - Using the special tool remove the upper fifth wheel seat by putting the special tool into the lower part of the headstock as indicated in the figure.
  • Page 103 NRG Power DT Suspensions Always use a new fifth wheel seat on refitting. - Using the special tool, refit the fifth wheel seat with the aid of a few mallet blows and bring it as far as the stop shown in the photo.

  • Page 104: Removing The Rear Wheel

    NRG Power DT Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFIT- TING.
  • Page 105 NRG Power DT Suspensions Centre-stand Removal of stand bolt from bracket - Remove the stand support bracket from the en- gine. - Drill a 5 mm hole in the bracket so that the pin «P» can come out. Replacing the centre-stand assy - Work on the screws shown in the figure.
  • Page 106 NRG Power DT Suspensions SUSP - 10...
  • Page 107 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 108 NRG Power DT Braking system Front brake calliper Removal • Check that the brake piping, gasket and fitting are in good condition. If you see any oil on the brake calliper and/on the components of the system, it is necessary to replace them.

  • Page 109: Front Brake Disc

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

  • Page 110: Front Brake Pads

    NRG Power DT Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring. Characteristic New rear disc thickness 4.0 mm...
  • Page 111 NRG Power DT Braking system Removal • Remove the pin split ring located at the back of the calliper body. • Remove the pin, paying attention in re- covering the spring, hence remove the pads. • The pads must be replaced if the work- ing thickness is less than 1.5 mm...
  • Page 112 NRG Power DT Braking system Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in...
  • Page 113 NRG Power DT Braking system THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE OIL ON IT. Specific tooling 020329Y MityVac vacuum-operated pump Recommended products AGIP BRAKE 4 Brake fluid...
  • Page 114 NRG Power DT Braking system 7. Gasket. 8 - Spring CAUTION - THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAK- ING EFFICIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY SOL- VENT.

  • Page 115: Rear Drum Brake

    NRG Power DT Braking system Rear drum brake After removing the muffler and the rear wheel do the following: 1. Remove the shoe spring with the special tool 2. Remove the shoe with the aid of a lever 3. Refit the new shoes giving a few taps with the mallet 4.
  • Page 116 NRG Power DT Braking system BRAK SYS - 10...
  • Page 117 INDEX OF TOPICS CHAS HASSIS...
  • Page 118 NRG Power DT Chassis Carrozzeria Frame central cover • Remove the top and bottom fairings. • Remove the 2 Philips screws fixing the footrest. • Remove the 3 Allen screws located around the fuel filler cap. • Remove the fuel filler cap.
  • Page 119 NRG Power DT Chassis Side fairings Footrest • Remove the centre frame cover. • Remove the 10 screws (5 for each side), hence remove the footrest. • Remove the side fairing from the foot- rest, by removing the two screws join- ing this to the spoiler and the knee- guard.

  • Page 120: Fuel Tank

    NRG Power DT Chassis • Remove the lower fairings, removing the 2 side screws and the central join- ing screw located underneath the spark plug cover. License plate holder • Remove the top fairing joining element located behind the taillight.
  • Page 121 NRG Power DT Chassis • Remove the metallic clip joining the rubber bellow to the tank and loosen the 3 screws fixing to the knee-guard • Remove the 2 top screws fixing the tank to the frame and lower the tank so to disconnect the inlet and outlet fuel hoses from the pump.
  • Page 122 NRG Power DT Chassis CHAS - 6...
  • Page 123 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 124 NRG Power DT Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...
  • Page 125 NRG Power DT Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
  • Page 126 NRG Power DT Pre-delivery Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 127 INDEX OF TOPICS TIME...
  • Page 128 NRG Power DT Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replace- ment TIME - 2...
  • Page 129 NRG Power DT Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replace- ment TIME - 3...
  • Page 130 NRG Power DT Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001118 Main bearings - Replacement 001099 Oil seal, flywheel side - Re- placement 001100 Oil seal, clutch side - Re- placement TIME - 4...
  • Page 131 NRG Power DT Time Cylinder assy. YLINDER PISTON Code Action Duration 001002 Cylinder piston - Replace- ment 001107 Cylinder / piston - Inspection / cleaning TIME - 5...
  • Page 132 NRG Power DT Time Cylinder head assy. YLINDER HEAD ASSEMBLY Code Action Duration 001013 Intake manifold - Replace- ment 001093 Spark plug - Replacement 001126 Head - Replacement 001097 Cooling hood - Replacement 001178 Disc pack - Replacement 001087 Flywheel cover - Replace-...

  • Page 133: Driven Pulley

    NRG Power DT Time Driven pulley RIVEN PULLEY Code Action Duration 001110 Driven pulley - Replacement 001022 Clutch - Replacement 001155 Clutch bell housing - Re- placement 001012 Driven pulley - overhaul TIME - 7...
  • Page 134 NRG Power DT Time Oil pump IL MIX PUMP Code Action Duration 001018 Mixer - Replacement 001019 Mixer belt - replacement 001028 Mix movement gear socket - Replacement TIME - 8...
  • Page 135 NRG Power DT Time Final gear assy. INAL REDUCTION GEAR Code Action Duration 001010 Geared reduction unit - Serv- 001156 Gear reduction unit cover - Replacement 003065 Gearcase oil - Replacement 004125 Rear wheel axle - Replace- ment TIME - 9...
  • Page 136 NRG Power DT Time Driving pulley RIVING PULLEY Code Action Duration 001011 Driving belt - Replacement 001066 driving pulley - Replacement 001017 Starter sprocket wheel - Re- placement 001086 Driving half-pulley - replace 001177 Variator rollers / shoes - Re-...

  • Page 137: Transmission Cover

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

  • Page 138: Water Pump

    NRG Power DT Time Water pump ATER PUMP Code Action Duration 001113 Water pump - Replacement 001062 Water pump command shaft - Replacement 007019 Connection water pump pipe / return pipe - Replace- ment TIME - 12...

  • Page 139: Starter Motor

    NRG Power DT Time Starter motor TARTER MOTOR AND KICK STARTER Code Action Duration 001020 Starter motor - Replacement 001021 Kick starter - Inspection 001084 Starter lever - Replacement 008008 Starter spring pack - Re- placement 005045 Starter motor cable harness -...

  • Page 140: Flywheel Magneto

    NRG Power DT Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001058 Flywheel - Replacement 001067 Stator - Replacement 001173 Rotor - Replacement 001109 Cooling fan - Replacement TIME - 14...
  • Page 141 NRG Power DT Time Brake shoes RAKE SHOES Code Action Duration 002002 Rear brake shoe(s) - Re- placement TIME - 15...
  • Page 142 NRG Power DT Time Carburettor ARBURETTOR INSPECTION Code Action Duration 001081 Automatic choke - Replace- ment 001008 Carburettor - Inspection TIME - 16...
  • Page 143 NRG Power DT Time Exhaust pipe UFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjust- ment TIME - 17...

  • Page 144: Air Cleaner

    NRG Power DT Time Air cleaner IR FILTER Code Action Duration 001014 Air filter - Replacement / cleaning 001015 Air filter box - Replacement 004122 Air cleaner carburettor fitting - Replacement TIME - 18...
  • Page 145 NRG Power DT Time Frame HASSIS Code Action Duration 001053 Stand bolt - Replacement 004004 Stand - Replacement 004001 Frame - replace 004015 Footrest - Replacement 004171 Stand support plate - Re- placement 004143 Footrest support - replace TIME - 19...
  • Page 146 NRG Power DT Time Legshield spoiler RONT SHIELD Code Action Duration 004065 Front shield rear section - Re- placement 004064 Front shield - Replacement 003087 Wheel housing - Replace- ment 004167 Grill / radiator cover - Re- placement 004176 Air vent - Replacement...
  • Page 147 NRG Power DT Time Side fairings ENTRAL COVER Code Action Duration 004053 Spoiler - Replacement 004178 Footrest - Replacement 004011 Central chassis cover - Re- placement TIME - 21...
  • Page 148 NRG Power DT Time Underseat compartment ELMET COMPARTMENT Code Action Duration 004059 Spark plug inspection flap - Replacement 004016 Helmet compartment - Re- placement 005046 Battery cover - Replacement TIME - 22...
  • Page 149 NRG Power DT Time Plate holder ICENSE PLATE HOLDER Code Action Duration 005022 Rear turn indicators - Re- placement 005068 Rear turn indicator bulb - Re- placement 005005 Taillight - Replacement 005023 Rear tail light support - Re- placement 005091...
  • Page 150 NRG Power DT Time Mudguard UDGUARDS Code Action Duration 004009 Rear mudguard - Replace- ment 004052 Bumper - Replacement 004002 Front mudguard - Replace- ment TIME - 24...
  • Page 151 NRG Power DT Time Fuel tank UEL TANK Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004011 Central chassis cover - Re- placement 004072 Fuel filter - Replacement 004110 Fuel tank hose - Replace- ment...
  • Page 152 NRG Power DT Time Tank oil IL TANK Code Action Duration 004017 Oil reservoir - Replacement 005018 Oil reservoir float - Replace- ment 004095 Oil reservoir cock - Replace- ment 004091 Oil reservoir hose - Replace- ment TIME - 26...
  • Page 153 NRG Power DT Time Rear shock-absorber EAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorbers - Re- placement TIME - 27...
  • Page 154 NRG Power DT Time Steering column bearings TEERING FIFTH WHEELS Code Action Duration 003002 Steering fifth wheel - Re- placement 003073 Steering clearance - Adjust- ment 004119 Bearing / upper steering fifth wheel - Replacement TIME - 28...
  • Page 155 NRG Power DT Time Handlebar components LHS HANDLEBAR COMPONENTS Code Action Duration 004066 Rear-view mirror - Replace- ment 002071 Left hand grip - Replacement 003059 Counterweight - Replace- ment 002037 Brake or clutch lever - Re- placement TIME - 29...
  • Page 156 NRG Power DT Time HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 002060 Complete throttle control - Replacement 002059 Right hand grip - Replace- ment 005017 Stop switch - Replacement 003059 Counterweight - Replace- ment 002024 Front brake pump - replace...
  • Page 157 NRG Power DT Time Swing-arm WINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement TIME - 31...
  • Page 158 NRG Power DT Time Seat Code Action Duration 004003 Saddle - Replacement 004054 Seat lock hook - Replace- ment 002083 Saddle opening transmission - Replacement TIME - 32...

  • Page 159: Instrument Panel

    NRG Power DT Time Instrument panel NSTRUMENT UNIT AND HANDLEBAR COVER Code Action Duration 005014 Odometer - Replacement 004018 Handlebar front section - Re- placement 004019 Handlebar rear section - Re- placement 005078 Odometer glass - Replace- ment TIME - 33...
  • Page 160 NRG Power DT Time Turn signal lights RONT LIGHT Code Action Duration 005067 Front turn indicator bulb - Re- placement 005008 Front headlamp bulbs - Re- placement 005002 Front headlamp - change 005012 Front turn indicator - Re- placement TIME - 34...

  • Page 161: Front Wheel

    NRG Power DT Time Front wheel RONT WHEEL Code Action Duration 002041 Front brake disc - Replace- ment 003040 Front wheel bearings - Re- placement 003037 Front wheel rim- Replace- ment 003047 Front tyre - Replacement 004123 Front wheel - Replacement...
  • Page 162 NRG Power DT Time In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel) Rear wheel EAR WHEEL Code Action Duration 001071 Rear wheel rim - Replace- ment 001016...

  • Page 163: Fuel Pump

    NRG Power DT Time Fuel pump UEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Pump / carburettor hose - Re- placement 004086 Petrol pump depression tube - Replacement TIME - 37...
  • Page 164 NRG Power DT Time Electric devices ATTERY Code Action Duration 005007 Battery - Replacement 005024 Battery fuse - Replacement 005025 Fuse holder - Replacement 005011 Start-up remote control switch - Replacement TIME - 38...
  • Page 165 NRG Power DT Time LECTRICS Code Action Duration 001023 Control unit - Replacement 001094 Spark plug cap - Replace- ment 005001 Electrical system - Replace- ment 005009 Voltage regulator - replace 005136 Resistance - Replacement 005044 Front lights cable unit- Re-...
  • Page 166 NRG Power DT Time Electronic controls LECTRICAL COMMANDS Code Action Duration 005041 Starter button - Replacement 005040 Horn button - Replacement 005016 Key switch - Replacement 004096 Lock series - Replacement 004010 Antitheft lock - replace 005003 Horn - Replacement...
  • Page 167 NRG Power DT Time Transmissions REAR BRAKE TRANSMISSIONS AND ODOMETER Code Action Duration 002053 Rear brake transmission complete - Replacement TIME - 41...

  • Page 168: Brake Callipers

    NRG Power DT Time PLITTER Code Action Duration 002012 Splitter - Replacement 002058 Mix / splitter transmission complete - Replacement 002057 Carburettor / splitter trans- mission complete - Replace- ment 002054 Throttle or splitter transmis- sion complete - Replacement Brake callipers...
  • Page 169 NRG Power DT Time Rear side fairings EAR COVERS Code Action Duration 004159 Plates / Stickers - Replace- ment 004056 Upper rear light cover - Re- placement 004036 Lower chassis cover - Re- placement 004085 Fairing (1) - Replacement 004129...

  • Page 170: Front Suspension

    NRG Power DT Time Front suspension Code Action Duration 003010 Front suspension - Service 003051 Complete fork - replace 003048 Fork oil seal - Replacement 003041 Fork stanchion - Replace- ment TIME - 44...
  • Page 171 NRG Power DT Time Secondary air box ECONDARY AIR SYSTEM Code Action Duration 001163 Muffler secondary air con- nection - Replacement 001165 Secondary air reed - Re- placement 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replace-...

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