Table Of Contents - Derbi GPR 125 Racing Workshop Manual

Table of Contents

Contents4
Safety Regulations5
Maintenance Regulations5
Vehicle Identification6
Racing 125 General Technical Data7
Preparation For Removal And Dismantling8
Spare Parts9
Seals, Retaining Rings And O-Rings9
Tab Washers/Spacers And Split Pins9
Bearings And Retaining Rings9
Locking Rings10
Special Tools10
Maintenance Specifications12
General Specifications12
Engine Specifications14
Engine Tightening Torques16
Chassis Specifications18
Electrical System Specifications20
General Tightening Torque Specifications22
Chassis Tightening Torques23
Periodic Maintenance / Lubrication Intervals25
Periodic Inspections And Adjustments26
Seats, Fairing And Fuel Tank27
Dismantling27
Refitting28
Engine29
Co Measurement And Vacuum Running Adjustment29
Adjusting The Throttle Cable30
Inspecting The Spark Plug31
Inspecting The Engine Oil Level33
Recommended Oil For The Engine33
Changing The Engine Oil33
Inspecting The Exhaust System34
Renewing Air Filter34
Adjuting The Clutch35
Adjusting The Front Brakes36
Adjusting The Rear Brakes36
Inspecting The Brake Pads36
Adjusting The Timing Chain Tension37
Inspecting The Tires38
Inspecting And Tightening The Spokes40
Inspecting The Wheels40
Inspecting The Battery40
Electrical System41
Inspecting The Fuses41
Adjusting The Headlight Beam43
Replacing The Headlight Bulbs43
Changing Turn Indicator Bulbs44
Changing The Side And Brake Light Bulbs44
Inspecting The Engine45
Dismantling The Engine45
Dismantling The Side Covers And Fuel Tank45
Engine On45
Removing The Engine From The Chassis46
Cylinder Head, Cylinder And Piston49
Dismantling The Reed Valve50
Magneto50
Clutch51
Gear Change Shaft54
Crankcase54
Balancer, Transmission And Gear Selector55
Crankshaft56
Cylinder Head56
Cylinder And Piston57
Inspection And Repair58
Inspecting The Piston Rings59
Inspecting The Balancer60
Inspecting The Clutch Bell Housings61
Inspecting The Clutch61
Inspecting The Actioning Rod63
Inspection Of The Forks And Gear Selector63
Crankcases65
Locking Rings And Washers65
Reassembling The Engine And Making Adjustments66
Valves, Rockers And Camshaft66
Crankshaft And Balancer Shaft67
Transmission68
Gear Selector69
Clutch And Clutch Bell Housing74
Installing The Clutch Bell Housing75
Fitting The Clutch75
Magneto And Starter Systems78
Inspecting The Starter Gear79
Magneto And Starter Gear79
Cylinder, Piston, Cylinder Head And Exhaust Valve81
Fitting Piston Rings, Piston And Cylinder82
Fitting The Cylinder Head83
Fitting The Reed Valve84
Refitting Engine Into The Frame85
Carburetor89
Adjusting The Fuel Level95
Front Wheel Diagram96
Chassis - Front Wheel And Brakes97
Inspecting The Front Wheel97
Inspecting The Speedometer99
Dismantling The Front Disk Calliper99
Assembling The Front Wheel105
Rear Wheel And Brakes107
Wheel Diagram107
Brake Diagram108
Rear Wheel And Brakes Dismantling109
Dismantling The Rear Disk Calliper109
Inspecting The Rear Wheel116
Fitting The Rear Wheel116
Transmission Dismantling117
Inspecting The Drive Chain118
Chain Sprocket118
Fitting The Chain Sprocket And The Drive Chain119
Fork120
Dismantling Front Suspension121
Inspecting The Front Forks123
Handlebars126
Handlebars Dismantling127
Inspecting The Half Handlebars128
Dismantling The Steering Column128
Inspecting The Steering Column128
Fitting The Half Handlebars129
Shock Absorber And Swinging Arm130
Shock Absorber And Swinging Arm Dismantling131
Shock Absorber And Swinging Arm Inspection131
Electrical System: Checking Connectors135
Inspecting The Switches136
Connections For The Switches Shown In This Manual136
Troubleshooting137