Derbi Rambla 250 Manual
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Derbi Rambla 250 Manual

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WORKSHOP MANUAL
RAMBLA 250

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  • Page 1 WORKSHOP MANUAL RAMBLA 250...
  • Page 3 This workshop manual has been drawn up by NACIONAL MOTOR, S.A.U.. Spa to be used by the workshops of DERBI dealers. This manual is addressed to Derbi service mechanics who are sup- posed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and proce- dures.

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Characteristics Rules Safety rules GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully. CAUTION USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START- ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY.
  • Page 8 Characteristics The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.

  • Page 9: Maintenance Rules

    Characteristics RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL- IST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL- LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE- THE BATTERY RELEASES EXPLOSIVE GASES.
  • Page 10 NOTE BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Use only ORIGINAL Derbi SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before refitting them.
  • Page 11 Characteristics • In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. • Make sure that the cables are correctly linked to the connector's internal terminal ends. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND.

  • Page 12: Vehicle Identification

    Characteristics Thus, mineral salt deposits formed in the radiator by evaporated water are also minimised and the efficiency of the cooling system is not affected. When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more antifreeze if needed (up to 60% max.). Use distilled water in the coolant mixture to avoid damaging the engine.

  • Page 13: Dimensions And Mass

    Characteristics Engine number The engine number is stamped near the rear shock absorber lower support. CAUTION ALTERING IDENTIFICATION NUMBERS CAN BE SERI- OUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY. Dimensions and mass DIMENSIONS Specification Desc./Quantity Max.

  • Page 14: Electrical System

    Characteristics Specification Desc./Quantity - maximum: 1:0.815 Capacities CAPACITY Specification Desc./Quantity Fuel (reserve included) Fuel reserve 1.5 l Engine oil change to service engine 1150 cm³ (70.18 cu.in3) Engine oil and engine oil filter change 1100 cm³ (67.12 cu.in) Transmission oil 250 cm³...

  • Page 15: Wheels And Tyres

    Characteristics Brakes BRAKES Specification Desc./Quantity Front brake Ø 260 mm (10.236 in) disc brake with hydraulic transmission Rear brake Ø 220 mm (8.6 in) disc brake with hydraulic transmission Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Wheel rims Made of light alloy Front wheel rim 2.75 x 15"...

  • Page 16: Crankcase And Crankshaft

    Characteristics Name Torque in Nm Driven pulley shaft nut 54÷60 (39.9÷44.3 ftlb) Rear hub cover screws 24÷27 (17.7÷19.9 ftlb) FLYWHEEL Name Torque in Nm Flywheel cover screw 11÷13 (8.1÷9.6 ftlb) Stator unit screws 3÷4 (2.2÷3 ftlb) (Apply LOCTITE 242 medium-strength thread- lock) Flywheel nut 94÷102 (69.4÷75.3 ftlb)

  • Page 17: Instrument Panel

    Characteristics INSTRUMENT PANEL Name Torque in Nm Right handlebar cover to left handlebar cover retainer 1±20% (0.74 ftlb) Windshield on handlebar cover retainer 1±20% (0.74 ftlb) Instrument panel on instrument panel support retainer 2±20% (1.48 ftlb) Instrument panel support on internal handlebar cover retainer 1±20% (0.74 ftlb) Internal handlebar cover on handlebar retainer 3±20% (2.22 ftlb)

  • Page 18: Front Wheel

    Characteristics FILTER HOUSING Name Torque in Nm Sleeve on carburettor retainer 2±20% (1.48 ftlb) Sleeve on filter housing retainer 2±20% (1.48 ftlb) Filter housing on engine retainer 8±20% (5.92 ftlb) COOLING UNIT Name Torque in Nm Thermal switch retainer 20±20% (14.8 ftlb) Head pipe on radiator retainer 2±20% (1.48 ftlb) Pump pipe on radiator retainer...

  • Page 19: Overhaul Data

    Characteristics Name Torque in Nm Fuel coupling clamp retainer 1±20% (0.74 ftlb) Tank to helmet compartment retainer 2±20% (0.74 ftlb) Petrol pump on helmet compartment retainer 2±20% (1.48 ftlb) Overhaul data Assembly clearances Cylinder - piston assy. Piston: the category marking is on the piston crown. Cylinder: the category marking is on the external side of the cylinder.
  • Page 20 Characteristics Crankcase - crankshaft - connecting rod CRANKSHAFT / CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft, transmission 16.6 +0-0.05 D = 0.20 ÷ 0.50 side Half shaft, flywheel side 16.6 +0-0.05 D = 0.20 ÷ 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 ÷...
  • Page 21 Characteristics Distance "A" to be measured is a value of piston recess, it indicates by how much the piston crown descends below the plane formed by the cylinder crown. The further the piston enters into the cylinder, the thinner the base gasket to be used should be (to compensate the compression ratio) and vice versa. NOTE DISTANCE «A»...
  • Page 22 Characteristics Product Description Specifications AGIP GEAR SYNTH SAE 75W-90 Gearbox oil API GL4, GL5 AGIP FORK 7.5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2 bearings and other points needing lubri- cation AGIP BRAKE 4 Brake fluid FMVSS DOT4+ SPECIAL AGIP PERMANENT fluid Coolant...

  • Page 23: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 24 Tooling PECIAL TOOLS Stores code Description AP8140259 Universal tool for clutch assemblies AP8140665 Adapter for clutch assembly removal AP8140535 Front pulley fitting/removal AP8140181 Fuel pressure check tool AP8140266 Comparator door AP8140729 Chain cover fitting/removal TOOL - 24...
  • Page 25 Tooling Stores code Description AP8140301 Flywheel extractor AP8140659 Valve oil seal punch AP8140662 Punch for roller casing 020425Y Shaft oil seal punch 020376Y Adapter handle 020455Y 10-mm guide for oil seal on water pump shaft 020412Y Clutch oil seal punch D 15 mm TOOL - 25...
  • Page 26 Tooling Stores code Description 020439Y Shaft 2 oil seal punch 17 mm 020359Y 42 x 47 mm punch 020363Y Crankshaft oil seal punch D 20 mm 020456Y Ø 24 mm punch 020364Y 25 mm Adaptor 020414Y 28 mm punch 020357Y 32x35 mm punch TOOL - 26...
  • Page 27 Tooling Stores code Description 020375Y 28x30 mm punch 020360Y 52x55 mm punch AP8140917 Tool for valve pressure plate AP8140661 Lock wrench for clutch bell AP8140300 55 mm wrench 020627Y Flywheel lock wrench AP8140179 Support for valve fitting/removal TOOL - 27...
  • Page 28 Tooling Stores code Description AP8140660 Piston fitting ring AP8140664 Guide to mount the movable driven pulley 020483Y 30 mm guide 020477Y 37-mm Adaptor 002095Y Engine support AP8140919 Valve oil seal extractor TOOL - 28...
  • Page 29 Tooling Stores code Description AP8140920 Tool for pin rings AP8140922 Crankcase splitting strip AP8140921 Oil seal punch 001467Y035 Bell for OD 47-mm bearings 020481Y Adaptor cable harness AP8140915 Crankcase check TOOL - 29...
  • Page 30 Tooling Stores code Description AP8140916 Hub cover support AP8140252 Multipurpose wrench AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) TOOL - 30...

  • Page 31: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 32: Maintenance Chart

    Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - Check Brake fluid - change 1,000 Action Safety locks - check Throttle lever - adjustment Oil filter - Replacement Electrical system and battery - Check Coolant level - check Brake fluid level - check Engine oil - Change Brake pad wear - check Tyre pressure and wear - check...
  • Page 33 Maintenance Action Electrical system and battery - Check Coolant level - check Brake fluid level - check Engine oil - Change Brake pad wear - check Sliding block/ variable speed rollers - Replacement Tyre pressure and wear - check Vehicle and brake test - test drive Hub oil - Change Suspensions - Check Steering - check up...

  • Page 34: Spark Plug

    Maintenance Spark plug Check and/or replace the spark plug following the instructions in the scheduled maintenance table. • Remove the spark plug regularly, clean off carbon scales, and replace spark plug if necessary. To reach the spark plug: • Remove the right inspection fairing. For removal and cleaning: •...
  • Page 35 Maintenance Locking torques (N*m) SPARK PLUG 12÷14 (8.9÷10.3 ftlb) • Check the gap between the electrodes with a thickness feeler gauge. • The gap should be 0.7 - 0.8 mm; adjust if necessary by carefully folding the earth electrode. • Make sure the washer is in good con- ditions.
  • Page 36 Maintenance Check • Park the vehicle on firm and level ground. • Rest the vehicle on its centre stand. • Unscrew and pull out the measuring cap-dipstick. • Clean the area in contact with oil with a clean cloth. • Screw the cap-dipstick fully down into its tube.

  • Page 37: Air Filter

    Maintenance • Unscrew and pull out the measuring cap-dipstick. • Place a +300 cm³ (18.3 cu.in) capacity container under the drain screw. Undo and remove the drain screw. • Wait until all the oil drains out and screw and tighten the drain screw. •...

  • Page 38: Engine Oil

    Maintenance • Remove the filter. • Wash the filtering element with clean non-inflammable or high volatility solvents and let it dry thoroughly. • Apply filter oil over the whole surface. CAUTION PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACE- MENT.

  • Page 39: Engine Oil Check

    Maintenance • Unscrew and remove the cartridge en- gine oil filter «4». • Unscrew and remove the oil drainage plug «3» and then drain all the engine oil into the collecting container. • Fit a new oil cartridge filter «4» and take special care to lubricate the filter sealing O-rings with oil.

  • Page 40: Engine Oil Top-Up

    Maintenance • Unscrew and pull out the measuring cap-dipstick «1». • Clean the area in contact with oil with a clean cloth. • Screw the cap-dipstick «1» fully down into its tube «2». • Pull out the cap-dipstick «1» again and read the level the oil reaches on the dipstick: MAX = maximum level.

  • Page 41: Engine Oil Filter

    Maintenance Engine oil filter Change the cartridge filter each time you change the oil. Use only the recommended type of oil to top- up and change. Make sure the O-rings of the pre-filter and the drainage plug are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug.

  • Page 42: Checking The Ignition Timing

    Maintenance • Remove the throttle grip cable. • Remove the throttle grip. THROTTLE GRIP REFITTING • Carry out the operations but in the re- verse order, making sure to match the hole (1) with the pin (2). Checking the ignition timing - Remove the plastic cap on the flywheel cover - Turn the flywheel until the reference mark «T»...

  • Page 43: Cooling System

    Maintenance ence mark is opposite the mark on the head, make the crankshaft turn once more. To use this reference mark, remove the spark plug and make the engine spin opposite its normal di- rection of rotation applying a calliper spanner to the camshaft control pulley casing.

  • Page 44: Braking System

    IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK REMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT. FOR REPAIRS, TAKE YOUR VEHICLE TO AN OFFICIAL DERBI DEALER. Recommended products SPECIAL AGIP PERMANENT fluid Coolant Biodegradable coolant, ready for use, with "long life"...

  • Page 45: Level Check

    Maintenance PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIR- CUIT. Level check CAUTION PURGE THE AIR IN THE SYSTEM IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER, EXCESSIVE ELASTICITY OR AIR BUBBLES IN THE CIRCUIT. DO NOT USE OR MIX DIFFERENT SILICON- OR PETROLEUM-BASED COOLANT TYPES.

  • Page 46: System Check

    Maintenance • Lift and remove the cover «1». • Remove the gasket «2». • Top-up the reservoir «3» with brake fluid up to the right level. • Follow the reverse order for refitting the components. CAUTION DO NOT SHAKE THE VEHICLE TO AVOID BRAKE FLUID SPLASHING DURING TOP-UP.
  • Page 47 Maintenance Front brake calliper THIS OPERATION APPLIES TO BOTH FRONT CALLIPERS To check brake pad wear: • Rest the scooter on its centre stand. • Remove the front brake calliper. • Carry out a visual inspection. Replace both brake pads when the friction material (even if in one brake pad only) is worn to about 1.5 mm (0.05 in).

  • Page 48: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 49 Troubleshooting Engine Excessive oil consumption/Exhaust smoke EXCESSIVE WEAR Possible Cause Operation Incorrect valve adjustment Adjust valve clearance adequately Overheated valves Remove the head and the valves, grind or replace the valves Deformed/worn valve seat Replace the head unit Worn cylinder, Piston ring worn or broken Replace the cylinder piston unit or the piston rings Piston rings worn, broken or not adequately fitted Replace the cylinder piston unit or just the rings...

  • Page 50: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 51 Electrical system KEY: ELE SYS - 51...
  • Page 52 Electrical system 1. Multiple connectors 2. Fuel sensor 3. Instrument panel 4. Water thermistor 5. Speed sensor 6. Left light switch 7. Horn 8. Key switch 9. Front stop switch 10. Rear stop switch 11. Right light switch 12. Rear left turn indicator 13.
  • Page 53 Electrical system 39. Front headlamp tail light 40. High-beam bulb 41. Low-beam bulb 42. Front left turn indicator 43. Complete front headlamp 44. Det. Blinker (only) 45. Kit for det. blinker (only) CABLE COLOUR Ar orange Az sky blue B blue Bi white G yellow Gr grey...
  • Page 54 Electrical system KEY: 1. Front turn indicators 2. Electric fan 3. Instrument panel 4. Battery 5. Coil 6. Rear light unit 7. Fuses 8. Spark plug 9. Fuel level sensor 10.Automatic starter 11.Voltage regulator 12.Control unit 13.Start-up relay 14.Horn 15.Front headlamp 16.Pick-up sensor 17.Water temperature sensor 18.Generator...
  • Page 55 Electrical system 1 Front turn indicators Turn indicator light: 12V - 10W 2 Electric fan 3 Instrument panel 4 Battery 12V - 10 Ah ELE SYS - 55...
  • Page 56 Electrical system 5 Coil Primary resistance: 0.2±10% Ohm at 20 °C (68 ° Secondary resistance: 2.9±10% Ohm at 20 °C (68 °F) 6 Rear light unit Tail light / stop light: 12V - 5/21W Turn indicator light: 12V - 10W 7 Fuses Main Fuses: 20A fuse (1):...
  • Page 57 Electrical system 9 Fuel level sensor Full tank 100 ± 10% Ohm Full tank 1200 ± 10% Ohm 10 Automatic starter Approximately 30 Ohm at 20 °C (68 °F) 11 Voltage regulator (SH640D) Recharging voltage: - to terminals, off-load: 13/15 V at 5000 RPM 12 Control unit MARELLI ELE SYS - 57...
  • Page 58 Electrical system 13 Start-up relay 12 V / 150 A 14 Horn LEB 12 V 4A 15 Front headlamp Low-/high-beam lights: 12 V - 55 W . H7 Front position light: 12V - 5W 16 Pick-up sensor Winding resistance: 105±10% Ohm at 20 °C (68 °F) 17 Water temperature sensor 100 (°C) 212 (°F) 144 Ohm 80 (°C) 176 (°F) 262 60 (°C) 140 (°F) 512 Ohm...
  • Page 59 Electrical system 18 Generator permanent magnet, 12 V - 300 W Stator coil resistance: 0.1 - 1 Ohm at 20 °C (68 °F) Off-load generated voltage: > 50 V to 5000 RPM CABLE COLOUR Ar orange Az sky blue B blue Bi white G yellow Gr grey...
  • Page 60 Electrical system Then fit the two connectors making sure that they couple correctly (if the relevant safety hooks are provided, you will hear them "click" into place). Conceptual diagrams 1. Magneto flywheel-Pick up 2. Voltage regulator 3. Injection electronic control unit 4.
  • Page 61 Electrical system 11. Starter motor 12. Start-up remote control switch 13. Starter button 14. Front stop switch 15. Rear stop switch 16. Horn 17. Horn button 18. Plug socket 19. Stop light remote control 20. Rear light unit A. Tail light/stop light twin bulb B.
  • Page 62 Electrical system Ignition 1. Magneto flywheel-Pick up 3. Injection electronic control unit 5. Engine stop switch 6. Main fuse 7. Key switch 8. Injection load remote control 9. Auxiliary fuses 10. Battery 38. Spark plug 39. HV coil Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple ELE SYS - 62...
  • Page 63 Electrical system Battery recharge and starting 1. Magneto flywheel-Pick up 2. Voltage regulator 6. Main fuse 7. Key switch 9. Auxiliary fuses 10. Battery 11. Starter motor 12. Start-up remote control switch 13. Starter button 14. Front stop switch 15. Rear stop switch 19.
  • Page 64 Electrical system Level indicators and enable signals section 3. Injection electronic control unit 5. Engine stop switch 6. Main fuse 7. Key switch 8. Injection load remote control 9. Auxiliary fuses 10. Battery 27. Fuel level transmitter 28. Scroll switch 29.

  • Page 65: Devices And Accessories

    Electrical system Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple Devices and accessories 1. Magneto flywheel-Pick up 3. Injection electronic control unit 5. Engine stop switch 6.
  • Page 66 Electrical system Lights and turn indicators 1. Magneto flywheel-Pick up 2. Voltage regulator 6. Main fuse 7. Key switch 9. Auxiliary fuses 10. Battery 20. Rear light unit A. Tail light/stop light twin bulb B. License plate light bulb 21. Front headlight assembly A.

  • Page 67: Checks And Inspections

    Electrical system Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple Checks and inspections Battery recharge circuit • Remove the battery from the vehicle. •...

  • Page 68: Safety Specifications

    Electrical system SAFETY SPECIFICATIONS CAUTION REMEMBER THAT THE ELECTROLYTIC FLUID CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR SKIN OR CLOTHES AND KEEP THE BATTERY AWAY FROM HIGH HEAT SOURCES OR SPARKS, SPECIALLY WHEN THE BATTERY IS BEING CHARGED, BECAUSE THE HYDRO- GEN RELEASED CAN BE HIGHLY EXPLOSIVE.
  • Page 69 Electrical system Clock adjustment • Press and hold the MODE «2» button longer than three seconds. The colon dividing hours- minutes starts flashing. • Each time the MODE «2» button is pressed, the hour value is increased for adjustment. • Pressing the MODE «2»...
  • Page 70 Electrical system When the battery is attached the software code is displayed on the instrument panel and the needle goes from 0 to the end of the scale and back to zero. With the key to ''ON'' for 3 seconds all the segments of the display will light up (except for the words Miles and Km) as well as all the foreseen warning lights.
  • Page 71 Electrical system If the instrument detects a null resistance (short circuit), all the segments light up but no other in- dication is shown. Temperature sensor The general alarm warning light turns on when the temperature is above 115°C (approx. 25 Ohm). If the instrument panel detects an infinite resist- ance (interrupted circuit), the general alarm warn- ing light turns on and the corresponding icon on...

  • Page 72: Connector Pinout

    Electrical system 2. If the tank is emptied with the engine off (with an external pump), when the vehicle is started, the gauge shows the fuel level in the tank before the emptying. In this case, also wait 80 seconds to read the true level.

  • Page 73: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 74 Engine from vehicle Exhaust assy. Removal CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. Silencer removal • Rest the vehicle on its centre stand. • Loosen the clamp (1) fixing the exhaust silencer to the manifold. • Undo and remove the three fixing screws (2).
  • Page 75 Engine from vehicle • Undo and remove the three fixing screws of the exhaust silencer. • Remove the exhaust system. Removal of the engine from the vehicle Preventively remove: • Helmet compartment. • Rear central cover. • Right and left fairings. •...
  • Page 76 Engine from vehicle • Unscrew the spark plug tube and re- lease its cable from any retainer. • Disconnect the lambda probe connec- tor. • Remove the injector connector. • Remove the fast-release fittings from the injector support. ENG VE - 76...
  • Page 77 Engine from vehicle • Remove the water temperature sensor connector. • Unscrew and remove the starter motor supply and ground nuts. • Disconnect the starter motor supply and ground cables and leads. • Working from the vehicle left side, re- move the generator connectors.
  • Page 78 Engine from vehicle • Hold the vehicle chassis by means of a hoister. • Working from the left side, unscrew and remove the nut and slide off the fixing pin of the shock absorber. • Working from the left side, unscrew and remove the nut and slide off the fixing pin of the shock absorber.
  • Page 79 INDEX OF TOPICS NGINE...

  • Page 80: Automatic Transmission

    Engine This section describes the operations to be carried out on the engine and the tools required. Automatic transmission Transmission cover - To remove the transmission cover, it is necessary to remove the plastic cover first by inserting a screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft lock-nut and washer.

  • Page 81: Removing The Driven Pulley Shaft Bearing

    Engine - Remove the 5 screws on the two different levels, as well as the small casing. Removing the driven pulley shaft bearing - Remove the seeger ring from the inside of the cover. - Remove the bearing from the crankcase. Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch...

  • Page 82: Removing The Driven Pulley

    Engine Baffle roller Plastic roller - Check that the roller shows no signs of abnormal wear and that it rotates freely. - Remove the special fixing screws as indicated in the photograph - Check the roller outside diameter does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt contain- ment edge on the engine crankcase side...

  • Page 83: Inspecting The Clutch Drum

    Engine Inspecting the clutch drum - Make sure that the clutch bell is not worn or dam- aged. - Measure the clutch bell inside diameter. Characteristic Clutch bell max. value Max. value: Ø 135 mm Clutch bell standard value Standard value: Ø 134 ÷ 134.2 mm Checking the bell working surface eccentricity - Fit the bell on a driven pulley shaft with 2 bearings (inside diameter: 15 and 17 mm).

  • Page 84: Removing The Clutch

    Engine Inspecting the clutch - 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. NOTE UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 85 Engine Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. NOTE USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY. NOTE BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGING THE O-RING SEAL. - Remove the 4 torque server pins and pull the half- pulleys apart.
  • Page 86 Engine - Remove the roller bearing using the specific punch. Specific tooling 020376Y Adapter handle 020456Y Ø 24 mm punch 020363Y Crankshaft oil seal punch D 20 mm Inspecting the driven fixed half-pulley • Measure the outside diameter of the pulley bushing.
  • Page 87 Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the 2 O- rings; - Measure the inside diameter of the movable half- pulley bushing. - Check the contact surface with the belt to make sure there are no signs of abnormal wear. - Check the riveted joints are functional.

  • Page 88: Refitting The Driven Pulley

    Engine Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch AP8140662 Punch for roller casing Refitting the driven pulley - Insert the new oil seals and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure. - Fit the half-pulley on the bushing.
  • Page 89 Engine Specific tooling AP8140664 Guide to mount the movable driven pulley Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring, when unloaded. Characteristic Standard length 123 mm limit after use 118 mm Refitting the clutch - Assemble the spring, clutch and driven pulley.
  • Page 90 Engine Refitting the driven pulley - Refit the clutch bell. Drive-belt - Make sure that the driving belt is not damaged. - Check belt for correct width. Characteristic Driving belt 250 4T - minimum width 19.5 mm Driving belt 250 4T - standard width 21.3 ±...

  • Page 91: Removing The Driving Pulley

    Engine Removing the driving pulley - Turn the crankshaft until the slots of the pulley are on a horizontal axis - With the specific tool remove the fixing nut, the Belleville spring and its washer - Remove the stationary driving half-pulley and the steel washer in contact with it Specific tooling AP8140535 Front pulley fitting/removal Inspecting the rollers case...
  • Page 92 Engine movable driving half-pulley bushing: Max. di- ameter admitted Ø 26.12 mm sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm sliding bushing: Minimum diameter admitted Ø 25.95 mm roller: Standard Diameter Ø 20.5 ÷ 20.7 mm roller: Minimum diameter admitted Ø...
  • Page 93 Engine - Fit the steel shim contacting the bushing and the stationary driving half-pulley. - Install the appropriate tool as described in the removal phase. - Tighten the nut and washer to the prescribed torque. Specific tooling AP8140535 Front pulley fitting/removal Locking torques (N*m) Driving pulley nut 75÷83 (55.4÷61.3 ftlb) Refitting the transmission cover...
  • Page 94 Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and the relevant gasket. Removing the wheel axle - Remove the wheel axle with gear. - Remove the intermediate gear.
  • Page 95 Engine Removing the wheel axle bearings - Remove the seeger ring from the outside of the hub cover. - Support the hub cover and expel the bearing. - Remove the oil seal as shown in the figure using the specific tool. Specific tooling 020376Y Adapter handle 020477Y 37-mm Adaptor...
  • Page 96 Engine - Remove the driven pulley shaft bearing. Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch 020363Y Crankshaft oil seal punch D 20 mm Inspecting the hub shaft - Check the three shafts for wear or distortions on the toothed surfaces, on the bearing housings and the oil seal positions.
  • Page 97 Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - warm the cover crankcase with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure. - Fit the seeger ring.
  • Page 98 Engine Refitting the hub cover bearings To fit the hub box bearings, the engine crankcase and the cover should be heated with the specific heat gun. - The three 15-mm bearings must be fitted using the appropriate tools: The 42-mm side of the adaptor should face the bearing.
  • Page 99 Engine Refit the driven pulley shaft bearing with a modular punch as shown in the figure. NOTE IF A BEARING WITH AN ASYMMETRICAL BALL RETEN- TION CAGE IS USED, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INTERNAL SIDE. Specific tooling 020376Y Adapter handle 020359Y 42 x 47-mm adaptor...

  • Page 100: Flywheel Cover

    Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the bleeding pipe using black silicone sealant. - Fit the cover making sure the bleeding pipe is in the correct position. - Position the shorter screw, easily recognisable by its different colour, as shown in the figure.

  • Page 101: Removing The Stator

    Engine Removing the stator - Remove the 2 Pick-Up screws and the one for the wiring bracket as well as the 3 stator fixing screws shown in the figure. - Remove the stator and its cable harness. Locking torques (N*m) Screws fixing freewheel to flywheel 13÷15 (9.6÷11.1 ftlb) Refitting the stator - Refit the stator and the flywheel carrying out the...

  • Page 102: Removing The Starter Motor

    Engine Refitting the flywheel cover - Position the keying clip on the crankshaft and orient the end as shown in the figure. - Orient the water pump shaft taking as reference the transmission gear seat as shown in the pho- tograph.
  • Page 103 Engine Removing the flywheel magneto - Remove the keying clip of the water pump shaft and crankshaft - Refit the driving half-pulley (if removed) - Lock the crankshaft rotation with a multipurpose wrench - Unscrew and remove the flywheel nut and its spacer - Do up the flywheel fixing nut by 3 or 4 threads so that the flywheel does not fall accidentally upon...

  • Page 104: Recommended Products

    Engine Inspecting the flywheel components - Check that the internal plastic parts of the flywheel and the Pick-Up control plate are in good conditions. Refitting the free wheel - Make sure the freewheel faying surfaces are in good condition. - Thoroughly clean the freewheel to remove any LOCTITE left. - Degrease the threading of the freewheel holes and the fixing screws.
  • Page 105 Engine Refitting the flywheel magneto - Remove the freewheel retention plate indicated in the photograph - Remove the transmission gear and the freewheel - Insert the freewheel on the flywheel as shown in the photo - Then refit the flywheel together with the free- wheel and transmission gear - Tighten the flywheel fixing nut to the prescribed torque with a multipurpose wrench - Refit the retention plate...

  • Page 106: Removing The Intake Manifold

    Engine Cylinder assy. and timing system Removing the intake manifold Loosen the 3 screws and remove the air intake manifold. When refitting, tighten the screws to the prescribed torque. Removing the rocker-arms cover Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: transmission cover, driving pulley with belt, oil sump with spring...
  • Page 107 Engine - Remove the return spring of the automatic valve- lifter assembly, the automatic valve-lifter assembly and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the 2 clamps indicated in the figure. - Remove the tensioner and its gasket.

  • Page 108: Removing The Cam Shaft

    Engine - Remove the command sprocket wheel and the timing chain. - Remove the screw indicated in the figure, the spacer and the tensioner pad. The tensioner pad must be removed operating from the transmission side. The lower chain guide pad can only be removed after the head has been removed.

  • Page 109: Removing The Cylinder Head

    Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side retainers indicated in the fig- ure. - Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-cross sequence. - Remove the head, the 2 centring dowels and the gasket.

  • Page 110: Inspecting The Small End

    Engine Removing the cylinder - piston assy. Cylinder and piston removal - Remove the chain guide pad. - Remove the 4 sealing O-rings on the stud bolts - Slide off the cylinder. - Remove the gasket on the cylinder base. - Remove the 2 seeger rings, the pin and the pis- ton.

  • Page 111: Inspecting The Piston

    Engine Inspecting the wrist pin - Check the pin outside diameter - Calculate the rod small end - gudgeon pin cou- pling clearance. Characteristic Pin diameter: Standard clearance 0.015 ÷ 0.029 mm Pin diameter: Standard diameter 14.996 ÷ 15.000 mm Inspecting the piston - Measure the pin seat diameter on the piston.

  • Page 112: Sealing Rings

    Engine piston diameter 71.953 ÷ 71.981 mm Fitting clearance 1st compression ring - standard coupling 0.015 ÷ 0.06 mm clearance 1st compression ring - 0.07 mm maximum clearance allowed after use 2nd compression ring - standard coupling 0.015 ÷ 0.06 mm clearance 2nd compression ring - 0.07 mm...

  • Page 113: Removing The Piston

    Engine THE PISTON AND THE CYLINDER ARE AS SPECIFIED. IN ANY CASE, NEW PISTON SEALING RINGS USED IN COM- BINATION WITH A USED CYLINDER MAY HAVE DIFFER- ENT BEDDING CONDITIONS THAN THE STANDARD ONES. Characteristic 1st compression ring Standard opening: 0.15 ÷ 0.30 mm 2nd compression ring Standard opening: 0.20 ÷...
  • Page 114 Engine AP8140920 Tool for pin rings Choosing the gasket Characteristic Compression ratio 250 version CR: 10.5 ÷ 11.5 : 1 NOTE DISTANCE «A» TO BE MEASURED IS A VALUE OF PISTON RECESS, IT INDICATES BY HOW DEEP THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE CYLINDER CROWN. THE FURTHER THE PISTON ENTERS INTO THE CYLINDER, THE THINNER THE BASE GASKET TO BE USED SHOULD BE (TO COMPENSATE THE COMPRESSION RATIO) AND VICE VERSA.
  • Page 115 Engine Refitting the piston rings Sealing rings fitting - Place the oil scraper spring on the piston. - Fit the oil scraper ring keeping the gap opposed to the spring union and the word "top" facing the piston crown. In any case, the chamfered side of the must be facing the piston crown.

  • Page 116: Inspecting The Cylinder Head

    Engine AP8140921 Oil seal punch AP8140660 Piston fitting ring Inspecting the cylinder head - Using a trued bar and a thickness gauge, check that the cylinder head surface is not worn or dis- torted. Maximum run-out allowed: 0.05 mm - Check that the camshaft and the rocker pin bear- ings show no sings of wear.
  • Page 117 Engine Inspecting the valve sealings - Fit the valves into the cylinder head. - Alternatively test the intake and outlet valves. - This test should be carried out by filling the mani- fold with petrol and checking that the head does not excessively ooze through the valves.
  • Page 118 Engine Valve seat wear: Outlet guide Standard diameter: 5.000 ÷ 5.012 mm Inspecting the valves - Measure the width of the sealing surface on the valve seats and on the valves themselves. Sealing surface width: After use: Intake and outlet: 1.6 mm - If the sealing surface on the valve is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.
  • Page 119 Engine - Measure the diameter of the valve stem at the three positions indicated in the diagram. - Calculate the clearance between the valve and its guide. - Check that there are no signs of wear on the fay- ing surface with the set screw articulated terminal. - If no anomalies are found during the above checks, the same valves can be reused.
  • Page 120 Engine Valve check: Standard diameter: Outlet: 4.96 ÷ 4.975 mm Inspecting the springs and half-cones - Check that the spring upper caps and the cotters show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head.

  • Page 121: Inspecting The Cam Shaft

    Engine Inspecting the cam shaft - Check the camshaft bearings for signs of abnor- mal wear. - Check the cam height. - Check there is no wear on the camshaft groove and related retention plate. - If values measured are not within the specified limits or there are signs of excessive wear, replace the defective components with new ones.
  • Page 122 Engine Camshaft check: Minimum diameter admitted Bearing B Ø: 19.950 mm Camshaft check: Minimum diameter admitted Bearing A Ø: 36.94 mm Camshaft check: Standard diameter Bearing B Ø: 19.959 ÷ 19.98 mm Camshaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm Refitting the head and timing system components - Fit the timing chain sprocket wheel on the crank- shaft, with the chamfer facing the insertion side.
  • Page 123 Engine - Fit the counterweight and tighten the fixing screw to the prescribed torque.. - Fit the end-stop ring on the automatic valve-lifter assembly and fit the automatic valve-lifter cam to the camshaft. - Fit the automatic valve-lifter return spring. During this operation the spring must be loaded approximately 180°.
  • Page 124 Engine Locking torques (N*m) Timing chain tensioner support screw 11÷13 (8.1÷9.6 ftlb) Spark plug 12÷14 (8.9÷10.3 ftlb) Starter ground screw 7÷8.5 (5.2÷6.3 ftlb) Timing chain tensioner pad screw 10÷14 (7.4÷10.3 ftlb) Starter ground bell screw 11÷15 (8.1÷11.1 ftlb) Timing chain tensioner central screw 5÷6 (3.7÷4.4 ftlb) Camshaft retention plate screw 4÷6 (3÷4.4 ftlb) - Fit the timing chain guide pad.
  • Page 125 Engine Locking torques (N*m) Timing chain tensioner support screw 11÷13 (8.1÷9.6 ftlb) Refitting the rocker-arms cover - Refit the head cover by tightening the 5 screws to the prescribed torque. - Take care to correctly position the gasket. Locking torques (N*m) Cylinder head cover screws 6÷7 (4.4÷5.2 ftlb) Refitting the intake manifold - Assemble the inlet manifold and tighten the 3...

  • Page 126: Crankcase - Crankshaft

    Engine Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with a specific tool dial gauge. - Higher clearances are signs of wear on the sup- porting surfaces of the crankshaft on the crank- case.
  • Page 127 Engine THE CRANKSHAFT CAN BE REUSED WHEN ITS WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING. CAUTION WHEN OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH- INGS.
  • Page 128 Engine Inspecting the crankshaft alignment - Install the crankshaft on the support and measure the misalignment at the 4 points indicated in figure. - Check that the crankshaft cone, the tab fitting, the oil seal flow, the knurling and the threaded tabs are in good working order.
  • Page 129 Engine Inspecting the crankcase halves - Before checking the crankcase halves, thorough- ly clean all the surfaces and oil pipes. - For the crankcase half on the transmission side, take particular care cleaning the housing and oil pipes of the oil pump, the duct and the by-pass valve, the main bushings and the cooling nozzle on the transmission side (see figure).
  • Page 130 Engine DUCE OIL TEMPERATURE. JET CLOGGING IMPAIRS HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DROP IN LUBRICATION PRES- SURE FOR THE MAIN BUSHINGS AND CONNECTING ROD. Inspecting the crankshaft plain bearings - In order to obtain proper bushing lubrication, it is necessary to have both an outstanding lubricating pressure (3.2 bar) and a good oil flow rate.
  • Page 131 Engine A spare crankcase cannot be combined with a crankshaft with mixed categories. Spare shafts have half-shafts of the same category. NOTE SPARE CRANKCASES ARE CHOSEN WITH HALF-SHAFTS OF THE SAME CATEGORY. - Fit the internal bulkhead by locking the 2 screws to the prescribed torque.
  • Page 132 Engine Locking torques (N*m) Screws for engine crankcase internal bulkhead (transmission-side half shaft) 4÷6 (3÷4.4 ftlb) Engine crankcase coupling screws 11÷13 (8.1÷9.6 ftlb) engine oil drainage plug/mesh filter 24÷30 (17.7÷22.1 ftlb) Oil filter fitting on crankcase 27÷33 (19.9÷24.4 ftlb) Studs Check that the stud bolts have not worked loose from their seats in the crankcase.

  • Page 133: Lubrication Circuit

    Engine Lubrication Conceptual diagrams LUBRICATION CIRCUIT ENG - 133...
  • Page 134 Engine ENG - 134...

  • Page 135: Oil Pressure Check

    Engine Oil pressure check - Disconnect the electrical connection of the mini- mum oil pressure switch and then remove the switch. - Check that the oil pressure reading is between 0.5 ÷ 1.2 atm with engine idling at 1650 rpm and oil at the required temperature (wait for at least one electric ventilation).
  • Page 136 Engine Removal - First remove the transmission cover and the en- tire driving pulley - Install the base of the appropriate tool on the oil guard using the screws supplied Specific tooling AP8140729 Chain cover fitting/removal - Screw the threaded bar onto the base of the tool and extract the oil guard Specific tooling AP8140729 Chain cover fitting/removal...
  • Page 137 Engine Refitting - Always use a new oil guard when refitting - Prepare the new oil guard by lubricating its seal- ing lip. - Preassemble the oil guard with the appropriate tool, positioning the screws. - Place the sheath over the crankshaft - Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase - Insert the adaptor bushing of the tool in the hole...

  • Page 138: Oil Pump

    Engine Specific tooling AP8140729 Chain cover fitting/removal Oil pump Removal - Undo the 2 clamping screws in the figure and re- move the cover over the pump control crown gear. - Block the rotation of the oil pump driving pulley by inserting a screwdriver through one of its holes.
  • Page 139 Engine Inspection - Remove the two screws and the oil pump cover. - Remove the circlip fixing the inner rotor. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the 2 reference marks visible.
  • Page 140 Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of wear or scoring on the oil pump cover. - If non-conforming values or signs of wear are found, replace the faulty parts or the assembly.
  • Page 141 Engine FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP TURNS FREELY. Locking torques (N*m) Screws fixing oil pump to crankcase 5÷6 (3.7÷4.4 ftlb) oil pump driving crown gear screw 10÷14 (7.4÷10.3 ftlb) Oil pump cover screws 7÷9 (5.2÷6.6 ftlb) Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and...
  • Page 142 Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate piece found in the sump.

  • Page 143: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 144 Injection MIU injection system This is an integrated ignition and injection system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tone wheel keyed onto the crankshaft (24-2 teeth) and a reluctant variation (pick-up) sensor. Carburetion and ignition are managed on the basis of the engine revs and throttle valve opening.
  • Page 145 Injection - HV coil - Injector The control unit is fitted with a self-diagnosis sys- tem connected to the EFI icon in the instrument panel display. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, data storage is automatically wiped clean after 16 cycles of use (cold start, running at regular engine temperature, stop).
  • Page 146 Injection TRANSPARENCY Specification Desc./Quantity Instrument panel Throttle body and injection electronic control unit (MIU) Connector for diagnosis Fuel pump Water Temperature Sensor Fuel injector HV coil Flywheel - revolution timing sensor Lambda Probe INJEC - 146...
  • Page 147 Injection Specification Desc./Quantity Injection load remote control Battery 12V - 12 Ah Electric fan remote control fall sensor Precautions Troubleshooting tips 1 A failure of the MIU system is more likely to be due to the connections rather than the components. Before searching the MIU system for failures, check: A: Power supply a.
  • Page 148 Injection 4 Use a multimeter with an internal resistance over 10K Ohm /V when troubleshooting. Do not use unsuitable instruments as they may damage the MIU control unit. Instruments with definitions over 0.1V and 0.5 W must be used. Precision must be greater than 2%. 1.
  • Page 149 Injection Terminals setup ERMINAL LAYOUT Specification Desc./Quantity Injection warning light lambda probe (-) permanent battery power supply (+) Battery (+) Electric fan remote control Water Temperature Sensor lambda probe (+) Engine stop switch Engine revolution sensor (+) Fuel injector Engine revolution sensor (-) Diagnosis output Ground connection Connected to: water temperature sensor, engine stop.
  • Page 150 Injection EMS circuit diagram SYSTEM DIAGRAM Specification Desc./Quantity Battery Lambda Probe Spark plug Fuse 15 A Fuel injector HV coil Front/ rear stop switches Fuse 15 A Key switch contacts Fuel pump Injection load remote control Starter button Start-up remote control Electric fan remote control Injection electronic control unit Starter motor...
  • Page 151 Injection Hand-held computer menu HANDHELD COMPUTER MENU SYMBOLS 1. ISO 2. Engine parameter reading 3. Device status (in general, values are ON - OFF) 4. Devices activation 5. Errors display 6. Adjustable parameters/Fixed parameters Specification Desc./Quantity Aprilia hardware (XXXXXX000) This is the mapping code with the numbers inverted. If there are only zeros, this means that the central unit is blank (no mapping): the suitable mapping should be remotely reloaded (see the note related to the mapping parameter)

  • Page 152: Device Status

    Injection DEVICE STATUS Specification Desc./Quantity Engine status (Off/running) Engine off or running Rpm sensor (Synchronised/Not synchron.) Synchronised if the control unit detects a correct synchronisa- tion (by means of the crankshaft rpm detection sensor Idle/full load (on/off) ON if idle functioning Active lambda probe (on/off) ON if the control unit is using the lambda probe signal to keep the stoichiometric combustion...

  • Page 153: Troubleshooting Procedure

    Injection The adjustable parameters screen page is used: • to align the throttle position sensor. Throttle position sensor alignment Align the throttle position sensor if the throttle body and/or the control unit should be replaced. • Select the function: "throttle position self-learn- ing".
  • Page 154 Injection Possible Cause Operation Correctness of the parameters Coolant temperature Intake air temperature Stepper throttle valve position (steps and actual opening) Cleaning the auxiliary air pipe and air filter efficiency throttle valve Engine stops at idle ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW Possible Cause Operation Faults detected by self-diagnosis...
  • Page 155 Injection Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause Operation Faults detected by self-diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda Probe Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system seal (seepage) Intake manifold - head...

  • Page 156: Fuel Supply System

    Injection Possible Cause Operation Lambda Probe Power to spark plug Spark plug Shielded cap HV Cable HV Coil Intake system Air filter Filter housing (seal) Intake sleeve (seal) Parameter reliability Throttle valve position signal Coolant temperature signal Intake air temperature signal Ignition advance Fuel supply Fuel level in the tank...

  • Page 157: Removing The Injector

    Injection Removing the injector Preventively remove: • Helmet compartment. • Rear central cover. • Remove the footrest lower protection by sliding it upwards and turning it. • Remove the injector connector. INJEC - 157...
  • Page 158 Injection • Remove the fast-release fittings from the injector support. • Undo and remove the screw. Refitting the injector For refitting, follow the operations in reverse order observing the tightening torque. Removing the butterfly valve • Remove the screws fixing the control unit cable harness support.
  • Page 159 Injection • Remove the MIU control unit connector • Unscrew the throttle body / sleeve fas- tening clamp. • Remove the sleeve. • Remove throttle control retainer. INJEC - 159...
  • Page 160 Injection Refitting the butterfly valve To refit, follow the removal steps but in reverse or- der, being careful to position the clip fixing the throttle body to the air filter bellows at 45° as shown in the photograph. INJEC - 160...
  • Page 161 Injection Pump supply circuit COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Key switch contacts Fuse 15 A Injection load remote control Fuel pump HV coil Fuel injector Lambda Probe INJEC - 161...

  • Page 162: Electrical Data

    Injection Specification Desc./Quantity Electric fan remote control When switched to "ON", the fuel pump starts to rotate for 2 seconds and then stops. With engine on and when a revolution timing signal is displayed, the pump is continuously supplied. ELECTRICAL DATA •...

  • Page 163: Specific Tooling

    Injection Upon switching to "ON", check that there is battery voltage for about two seconds between the Red- Brown cable of the pump connector and earth connection, with pump connector disconnected. Other- wise, check the continuity of the Red-Brown cable between the pump connector and the injection relay. Check the efficiency of the earth line of the fuel pump by measuring the continuity between the pump connector blue cable, system side, and the earth connection.
  • Page 164 Injection BAR. Check that within 15 seconds the pump has a flow rate of approx. 110 cm³. Specific tooling AP8140181 Fuel pressure check tool Fuel filter check Disconnect the terminals of the electrical pump Remove the screw indicated in the photograph Remove the clip fixing the piping to the filter shown in the photograph INJEC - 164...
  • Page 165 Injection Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 165...
  • Page 166 Injection Inspecting the injector circuit COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Key switch contacts Fuse 15 A Injection load remote control Fuel pump HV coil Fuel injector Lambda Probe INJEC - 166...
  • Page 167 Injection Specification Desc./Quantity Electric fan remote control Checking the resistance at the injector ends: 14.5 ± 5% Ohm Check the efficiency of 15A fuse No.4 of the injection load. Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷...
  • Page 168 Injection Check there is fixed voltage between the Green- Red cable of the remote control base and the earth connection. If there is none, check the continuity of the Green-Red cable between the fuse box (No. 4 15A) and the remote control base. NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
  • Page 169 Injection With both the control unit and the injector discon- nected, check the continuity of the Grey-Red cable between pin 14 of the interface wiring and the in- jector connector Switch to "ON" and check there is voltage, with in- jector disconnected and control unit connected, between the Red-Brown cable of the injector con- nector and the earth connection...
  • Page 170 Injection Inspecting the injector hydraulics To check the injector, remove the intake manifold by removing the three fixing screws at the head and the clip connecting the control unit to the mani- fold Fit the appropriate tool to check fuel pressure check and position the manifold over a scaled con- tainer at least 100 cm³.
  • Page 171 Injection Components location INJEC - 171...

  • Page 172: Components Layout

    Injection COMPONENTS LAYOUT Specification Desc./Quantity Instrument panel Throttle body and injection electronic control unit (MIU) Diagnosis socket Fuel pump Water Temperature Sensor Fuel injector HV coil Flywheel - revolution timing sensor Lambda Probe Injection load remote control Battery 12V - 12 Ah Electric fan remote control fall sensor Tachometer...
  • Page 173 Injection Disconnect the fuel pump connector. Start the en- gine and wait for it to stop. With the wiring con- nected to the control unit and the system, try to start-up the engine and check that the alternating voltage between pins 13 and 15 is over 2.5 V ~ With the interface cabling disconnected from the control unit, check the continuity of the rpm sensor connector red cable between pin 13 and pin 1 and...
  • Page 174 Injection HT coil COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Key switch contacts Fuse 15 A Injection load remote control Fuel pump HV coil Fuel injector Lambda Probe INJEC - 174...
  • Page 175 Injection Specification Desc./Quantity Electric fan remote control The combined ignition/injection system is a high-efficiency induction system. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure. With engine at idle speed, it is optimised to stabilise the speed at 1450 ±...
  • Page 176 Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷ 120 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
  • Page 177 Injection Check there is fixed voltage between the Green- Red cable of the remote control base and the earth connection. If there is none, check the continuity of the Green-Red cable between the fuse box (No. 4 15A) and the remote control base. NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.

  • Page 178: Coolant Temperature Sensor

    Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water Temperature Sensor Engine stop switch INJEC - 178...
  • Page 179 Injection On the interface wiring with the control unit side connector disconnected and the coolant tempera- ture sensor connector connected, check the re- sistance values between pins 9 and 26 in relation to the engine temperature. 20° = 2500 ± 100 Ω 80°...
  • Page 180 Injection After the pre-calibration the throttle body has an open valve with a variable angle depending on the tolerances of the machining of the pipe and the valve itself. The valve position sensor can also have various fitting positions. For these reasons the mVs of the sensor with the valve at idle can vary from one throttle body to another.
  • Page 181 Injection Given that the TPS reset is also carried out when the control unit is replaced, place the control unit - filter box bellows fixing clip at 45° upon refitting as shown in the photograph. INJEC - 181...

  • Page 182: Lambda Probe

    Injection Lambda probe COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Key switch contacts Fuse 15 A Injection load remote control Fuel pump HV coil Fuel injector Lambda Probe INJEC - 182...
  • Page 183 Injection Specification Desc./Quantity Electric fan remote control The lambda probe or oxygen sensor is a sensor which provides information about the oxygen content in the exhaust fumes. The signal generated is not of the proportional but of the ON/OFF type, i.e. whether there is oxygen or not.
  • Page 184 Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷ 120 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
  • Page 185 Injection Check there is fixed voltage between the Green- Red cable of the remote control base and the earth connection. If there is none, check the continuity of the Green-Red cable between the fuse box (No. 4 15A) and the remote control base. NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.

  • Page 186: Signal Check

    Injection SIGNAL CHECK Install the electronic control unit interface wiring. Start the engine and warm it up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2V. Place the multimeter probes between pins 4 (-) and 11 (+) With the engine running at idle speed, check that the voltage oscillates between 0V and 1V...

  • Page 187: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 188: Removing The Front Wheel

    Suspensions Front Removing the front wheel KEY: 1. Grey front wheel rim; 2. Bearing; 3. Spacer; 4. Front wheel left spacer; 5. Front wheel right spacer; 6. Front wheel pin; 7. Tubeless valve; 8. Front brake disc (Qty. 2); 9. TE flanged screw; 10.
  • Page 189 Suspensions Rest the scooter on its centre stand. • Place a support under the chassis. • Remove the brake calliper. • Loosen the pin locking screw. CAUTION UPON REMOVING/REFITTING, PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES, DISCS AND PADS. •...

  • Page 190: Front Wheel Hub Overhaul

    Suspensions INSERT THE BEARINGS. DO NOT HIT THE BALLS AND/OR THE INTERNAL RING. MAKE SURE THE FOLLOWING COMPONENTS ARE FITTED PERFECTLY IN: • THE LEFT BEARING «4» ON THE HUB; • THE SPACER «5» ON THE LEFT BEARING «4»; • THE RIGHT BEARING «2»...

  • Page 191: Refitting The Front Wheel

    Suspensions Check the tyre conditions. CAUTION CHECK TYRE TREAD FOR WEAR. BADLY WORN TYRES COMPROMISE TRACTION AND VEHICLE HANDLING. REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC- TURE BIGGER THAN 5 MM IN THE TREAD. SOME TYRE TYPE-APPROVED FOR THIS VEHICLE FEATURE WEAR INDICATORS.
  • Page 192 Suspensions • Disconnect the handlebar electrical control connectors. • Undo and remove the two screws. • Lower the brake pump U-bolt. • Remove the brake pump; keep it con- nected to the brake pipe. SUSP - 192...
  • Page 193 Suspensions • Disconnect the throttle grip cable. • Remove the brake pump U-bolt. • Remove the throttle grip. • Remove the safety screw «2». • Loosen the main screw «1». • Slide off the handlebar upwards. Refitting For refitting, follow the operations in reverse order observing the tightening torque. SUSP - 193...

  • Page 194: Front Fork

    Suspensions Front fork KEY: 1. Fork base 2. Fork clamp screws 3. Snap ring 4. Rubber cap 5. Sealing cap 6. O-ring 7. Spring 8. Pumping member 9. Counter spring 10. Bottom buffer 11. Left stem 12. Dust guard gasket 13.
  • Page 195 Suspensions 20. Right stem 21. Right wheel holder 22. Locking screw Removal STEM REMOVAL • Remove the front wheel. • Remove the front mudguard. • Undo and remove the two screws «1». NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE WHEEL HOLDER STEM - SLEEVE, BUT THEY APPLY TO BOTH.
  • Page 196 Suspensions • Undo and remove the lower screw «1». • Remove the stem and collect the cen- tring bushing. NOTE BE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIOR WHEN REMOVING THE DIFFERENT COMPONENTS. • Remove the pumping member «2» and the spring «3»...
  • Page 197 Suspensions • Remove the Seeger ring. • Remove the oil seal. • Remove the washer. • If necessary, remove the spacer «4». SUSP - 197...
  • Page 198 Suspensions OIL EMPTYING Place the sleeve in a vice fitted with protection jaws (aluminium). NOTE GET A COLLECTING CONTAINER BEFORE CARRYING OUT THESE OPERATIONS. CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL. DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT.
  • Page 199 Suspensions • Remove the spring and wait some mi- nutes so that the oil deposited on it drips off. • Drain off the oil into the collecting con- tainer by pumping it out with the stem. Overhaul Components check Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (fine grain).

  • Page 200: Oil Filling

    Suspensions • Check that there are no damages and/ or cracks; otherwise, replace it. • If there are signs of excessive wear or damage, replace the affected compo- nent. Replace the following components with new ones: • O-ring gasket on the cap «1»; •...
  • Page 201 Suspensions • Pour fork oil into the wheel holder stem sleeve unit. CAUTION NEVER REUSE OIL. • Remove the cap with the O-ring. • Fit the pumping member «1». • Lower the pumping element until the Seeger ring «2» can be fitted. •...
  • Page 202 Suspensions • Fit the upper closing cap. Refitting • Place the sleeve in the vice fitted with protection jaws (aluminium). • Fit the spacer «1». CAUTION BE EXTREMELY CAREFUL SO THAT NO FOREIGN BOD- IES GET INTO THE SLEEVE OR THE WHEEL HOLDER STEM.
  • Page 203 Suspensions • Fit the Seeger ring. • Fit the dust guard. • Insert the pumping member and the spring in the stem. • Fit the components below on the sleeve in the following order: the cen- tring bushing «2» and the stem. SUSP - 203...

  • Page 204: Steering Column

    Suspensions • Tighten the lower screw «3». • Refill with oil. Steering column KEY: 1. Cap; 2. Lock nut; 3. Adjusting nut; 4. Upper dust guard; 5. Upper bearing; 6. Separating ring; 7. Lower bearing; 8. Lower dust guard. SUSP - 204...

  • Page 205: Steering Bearing

    Suspensions Steering bearing Check that the ball contact area «1» on the rotating seat «2» and on the fixed seat «3» is not damaged or too worn. Replace the whole bearing if neces- sary. CAUTION CHECK THAT THE COMPONENTS ARE IN GOOD CONDI- TIONS.

  • Page 206: Refitting The Rear Wheel

    Suspensions 8. Brake disc; *9. TE flanged screw; 10. SPEED SENSOR screw; 11. Tubeless valve. • Rest the vehicle on its centre stand. • Remove the exhaust silencer. • Remove the rear right shock absorber. • Slide off the rear brake calliper and keep it connected to the oil pipe.
  • Page 207 Suspensions Removal • Unscrew the upper nut and remove the screw. • Lower the shock absorber. • Unscrew and remove the nut «2» and collect the washer. • Remove the screw «3». • Slide off the left shock absorber. • Unscrew and remove the nut «1».

  • Page 208: Centre-Stand

    Suspensions Centre-stand • Working from the scooter right side, disconnect the spring «1» from the stand hook «2». • Undo and remove the screw «3» and collect the self-locking nut. • Remove the centre stand. NOTE CARRY OUT THE FOLLOWING OPERATIONS FROM THE OPPOSITE SIDE OF THE STAND.

  • Page 209: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 210: Rear Brake Calliper

    Braking system KEY: 1. Front brake lever pipe, front brake calliper 2. Front brake pump /fluid reservoir 3. Front brake control lever 4. Rear brake pump/reservoir 5. Rear brake control lever 6. Rear brake calliper 7. Rear brake pads 8. Rear brake lever pipe, rear brake calliper 9.
  • Page 211 Braking system Removal • Undo and remove the two fixing screws. • Slide off the brake calliper from the disc. Front brake calliper OPERATIONS VALID FOR BOTH FRONT CALLIPERS Removal • Undo and remove the two fixing screws. • Slide off the brake calliper from the disc.

  • Page 212: Front Brake Disc

    Braking system Disc Inspection • Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated. • Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points. Replace the disc if the minimum thickness, even at a single point of the disc, is less than the minimum value.

  • Page 213: Front Brake Pads

    Braking system CAUTION UPON REFITTING, APPLY THE RECOMMENDED PRODUCT ON THE THREADING OF THE BRAKE DISC SCREWS. Recommended products LOCTITE® 243 Loctite adhesive to assembly cylindrical pieces Loctite adhesive to assembly cylindrical pieces Disc Inspection • Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated. •...

  • Page 214: Rear Brake Pads

    Braking system • Loosen and slide off both pins. • Slide off the brake pads. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER; OTHERWISE, THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAK- AGE.
  • Page 215 Braking system Removal • Remove the Seeger ring. • Slide off the pin. • Remove the spring. CAUTION THE ARROW STAMPED ON THE SPRING MUST ALWAYS BE TURNED IN THE RIDING DIRECTION. • Slide off the brake pads. Refitting CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED.

  • Page 216: Air Bleeding

    Braking system For refitting, follow the operations in reverse order observing the tightening torque. Fill - Bleeding the braking system FILLING NOTE THESE OPERATIONS REFER TO ONE BRAKING CIRCUIT BUT APPLY TO BOTH. • Remove the rubber protection cover from the bleed valve «4» and «5». •...
  • Page 217 Braking system If there is air in the hydraulic circuit, it acts as a bearing, absorbing a large quantity of the pressure from the brake pump and minimising calliper efficiency when braking. The presence of air is signalled by the "sponginess"...
  • Page 218 Braking system • When only brake fluid comes out, tight- en the bleed valve «4» and «5» and release the brake lever. • Refit the cover «1» NOTE AFTER REFITTING, PULL THE BRAKE LEVER REPEAT- EDLY AND CHECK THE CORRECT OPERATION OF THE BRAKING SYSTEM.

  • Page 219: Cooling System

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 220: Circuit Diagram

    Cooling system Circuit diagram KEY: 1. Expansion tank with cap; 2. Radiator / fitting pipe; 3. Radiator fitting / pump pipe; 4. Clamp; 5. Breather pipe; 6. White clic clamps; 7. White clic clamp; 8. Expansion tank cap; 9. Clip; 10.
  • Page 221 Cooling system Electric fan check • Check via Axone if there is a "Fan re- lay" error. If there is such error: • check the relay and the cable harness between fan relay and Pin 8 of the con- trol unit. If there is not such error: •...

  • Page 222: Coolant Replacement

    Cooling system • Remove the front central cover. • Disconnect the electric fan connector. CAUTION OPERATE WITH CAUTION SO AS NOT TO DAMAGE THE RADIATOR FINS. • Undo and remove the three screws. • Remove the electric fan. Coolant replacement Emptying NOTE USE A CONTAINER OF ADEQUATE CAPACITY TO COLLECT THE FLUID THAT MAY LEAK DUR-...
  • Page 223 Cooling system Filling • Reposition the coolant delivery pipe and tighten with a clamp. • Remove the central inspection cover (SEE TAIL). • Remove the rubber cap «1» of the bleed screw of thermostat «2» and fit a hose. The other end of the hose should be fitted into in a container.
  • Page 224 Cooling system - Tighten the bleed valve respecting the maximum torque. - Refill with coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleed screw: Thermostat Removal Preventively remove: • Helmet compartment. • Rear central cover. •...
  • Page 225 Cooling system Check 1) Visually check that the thermostat is not dam- aged. 2) Fill a metal container with approx. 1 litre of wa- ter. Immerse the thermostat, and keep it in the centre of the container. Immerse the multimeter thermometer probe, and keep it close to the thermostat.
  • Page 226 INDEX OF TOPICS CHAS HASSIS...

  • Page 227: Rear Rack

    Chassis Seat • Insert the key in the saddle lock. • Turn the key anticlockwise. • Lift the saddle. • Undo and remove the four screws. • Remove the saddle. Rear rack • Insert the key in the saddle lock. •...
  • Page 228 Chassis • Undo and remove the screw. • Remove the luggage rack. Driving mirrors • Operating from both sides, unscrew the mirror. CAUTION THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK- WISE. Rear handlebar cover • Operating from both sides, undo and remove the two screws.
  • Page 229 Chassis • Undo and remove the screw. • Disconnect the connector. Instrument panel • Remove the rear handlebar cover. • Undo and remove the four screws. • Pull the instrument panel backwards. CHAS - 229...
  • Page 230 Chassis • Undo the three screws. • Slide off the instrument panel forwards. Front handlebar cover • Remove the rear handlebar cover. • Remove the front handlebar cover. CHAS - 230...
  • Page 231 Chassis Legshield • Remove the front mudguard. • Remove the front wheel. • Remove the central front cover. • Operating from both sides, undo and remove the five screws. CAUTION PLACE A SUPPORT UNDER THE CHASSIS SO THAT THE FRONT WHEEL DOES NOT TOUCH THE GROUND.
  • Page 232 Chassis • Operating from both sides, undo the two screws and remove the front turn indicators from the back. • Slide the external front shield off the front fork. Knee-guard • Remove the front central cover. • Operating from both sides, undo and remove the screw.
  • Page 233 Chassis • Insert the key in the glove-box lock, turn it clockwise and open the com- partment. • Undo and remove the four screws. • Close the glove-box. • Operating from both sides, undo and remove the four side screws. •...
  • Page 234 Chassis • Operating on both sides, undo and re- move the two screws of the footrest. • Remove the battery. • Unscrew and remove the bolt inside the battery compartment. • Operating from both sides, undo and remove the lower screw fixing it to the internal legshield.
  • Page 235 Chassis • Undo and remove the screw. • Undo and remove the screw. • Push aside the tail section. • Remove the fairing by sliding it off the hooks, being careful with the tongues and related fitting slots. Passenger footrest removal •...
  • Page 236 Chassis Air filter Air filter removal • Undo and remove the nine screws. • Remove the filter casing cover. • Remove the filter. Filter casing removal • Remove the helmet compartment. • Remove the rear central cover. • Remove the left under sear fairing. •...
  • Page 237 Chassis CHAS - 237...
  • Page 238 Chassis • Undo and remove the two screws and remove the filter casing front locking. • Move the filter housing leftwards. • Release the clamp of the oil breather pipe. • Remove the oil breather pipe. • Remove the filter casing. Tail guard •...
  • Page 239 Chassis • Undo and remove the two screws in- side the helmet compartment. • Operating on both sides, undo and re- move the screw. • Undo and remove the three fixing screws. CHAS - 239...
  • Page 240 Chassis • Remove the fairing of the tail light. • Remove the tail section from it fittings with the side fairings. • Move the tail section backwards and disconnect the rear light connector. • Undo the two fixing screws and remove the seat lock.

  • Page 241: Rear Mudguard

    Chassis Rear mudguard • Undo and remove the three screws. • Undo the three screws and remove li- cense plate. • Undo and remove the screw. • Undo and remove the screw. CHAS - 241...
  • Page 242 Chassis • Undo the screw and slide off the li- cense plate light backwards. • Remove the bulb but keep it connected to the cables • Remove the rear mudguard. Should the rear mudguard holder frame be re- moved before taking out the rear mudguard pro- ceed as follows: •...
  • Page 243 Chassis • Undo and remove the two screws. • Operating on both sides, undo and re- move the screw. • Remove the fuel tank cap «3». • Remove the gasket «4» and release it by sliding it off from the breather pipe «5». •...

  • Page 244: Fuel Tank

    Chassis • Slide off the helmet compartment for- wards. Fuel tank Tank Removal • Remove the helmet compartment. • Operating on both sides, undo and re- move the two screws and collect the washers. • Disconnect the connector. • Disconnect the connector 1. •...

  • Page 245: Front Mudguard

    Chassis • Remove the helmet compartment. • Disconnect the fuel probe. • Unscrew and slide the probe off the tank. NOTE USE A CLOTH IN ORDER TO AVOID FUEL SPLASHES. CAUTION ONCE THE PROBE IS REMOVED FROM THE TANK, CLOSE THE PROBE ENTRY OPENING WITH A CLOTH TO AVOID INHALING THE PETROL BEING EVAPORATED FROM THE TANK.

  • Page 246: Radiator Fan

    Chassis Rear central cover Right inspection cover removal • Remove the right fairing. • Remove the inspection cover by sliding it off its hooks, being careful with the tongues and related fitting slots. • Lift the saddle. • Undo and remove the two screws. •...
  • Page 247 Chassis • Loosen the clamps and remove the three pipes. • Undo and remove the screw. • Slide off the radiator upwards. CHAS - 247...

  • Page 248: Expansion Tank

    Chassis Expansion tank Drain off the cooling system: • Remove the front central cover. • Remove the shield back plate. • Loosen and remove the clamp. • Loosen and remove the clamp. NOTE UPON REFITTING, REPLACE THE REMOVED CLAMPS WITH NEW ONES. •...

  • Page 249: Radiator Cover

    Chassis • Slide off the windshield. Fairing removal • Operating from both sides, undo and remove the screw. • Detach the front right handlebar cover from the left one. Radiator cover • Operating on both sides, undo and re- move the screw. CHAS - 249...

  • Page 250: Lower Cover

    Chassis • Remove the front case by sliding it off its hooks, being careful with the tongues and related fitting slots. Lower cover NOTE THE FOLLOWING OPERATIONS REFER TO ONE SIDE OF THE VEHICLE, BUT APPLY TO BOTH. • Undo and remove the rear screw. •...
  • Page 251 Chassis • Undo and remove the screw fixing it to the legshield on the front wheel hous- ing. • Undo and remove the screw. • Lift the footrest and slide the lower shield off its hooks being careful with the tongues and related fitting slots. The lower shield can be split into right and left sec- tions.
  • Page 252 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 253 Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
  • Page 254 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

  • Page 255: Static Test

    Pre-delivery - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present) Functional inspection...
  • Page 257 Accessories: 65 Air filter: 37, 236 Battery: 63, 67 Brake: 210–214 Clutch: 49, 83, 84, 89 Coolant: 178, 222 Display: Engine oil: 38 Fork: 194 Fuel: 156, 164, 244 Hub oil: 35 Identification: 12 Instrument panel: 229 Maintenance: 9, 32 Mirrors: 228 Oil filter: 41 Recommended products:...
  • Page 258 Tank: 244, 248 Technical data: Transmission: 13, 80, 93 Turn indicators: 66 Tyres: 15...

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