Derbi boulevard 125 4t Workshop Manual
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Derbi boulevard 125 4t Workshop Manual

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WORKSHOP MANUAL
BOULEVARD 125 4T

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  • Page 1 WORKSHOP MANUAL BOULEVARD 125 4T...
  • Page 3 WORKSHOP MANUAL BOULEVARD 125 4T This workshop manual has been drawn up by Derbi. Spa to be used by the workshops of Derbi dealers. This manual is addressed to Derbi service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.

  • Page 6: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original DERBI 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 8: Vehicle Identification

    Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix (125) ZAPM42100 ÷ 1001 Engine prefix (125) M421M ÷ 1001 Chassis prefix (150) ZAPM42200 ÷ 1001 Engine prefix (150) M422M ÷ 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Dry weight 112 kg Overall height 1150 mm...
  • Page 9 Characteristics Engine ENGINE Specification Desc./Quantity Engine Single-cylinder, 4-stroke Piaggio LEADER Timing system Single overhead camshaft (SOHC) with 2 valves Valve clearance intake 0.10 outlet 0.15 Bore x stroke (125) 57 x 48.6 mm Bore x stroke 62,6 x 48.6 mm Cubic capacity (125) 124 cm³...

  • Page 10: Electrical Components

    Characteristics Transmission TRANSMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator with tor- que server, V belt, automatic clutch, gear reduc- tion unit and transmission housing with forced air circulation cooling. Capacities CAPACITY Specification Desc./Quantity Engine oil 61 in³ (1,000 cm³) Rear hub oil ~ 200 cm³...

  • Page 11: Wheels And Tyres

    To ensure the best functioning of the SAS system, every 12,000 km the scooter should be taken to an Authorised Derbi Service Centre to have the filter cleaned (Scheduled maintenance operations section). The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.

  • Page 12: Carburettor Setting

    Characteristics CONTACT AN AUTHORISED DERBI SERV- ICE CENTRE TO CARRY OUT THESE OPERA- TIONS. Carburettor 125cc Version Kehin CARBURETTOR SETTING Specification Desc./Quantity Type CVEK26 Throttle valve diameter Ø 26.5 Diffuser diameter Ø 26.4 Setting stamping 262A Maximum jet Maximum air jet (on the body)

  • Page 13: Tightening Torques

    Characteristics Specification Desc./Quantity Starter resistance 20 Ohm (at 24°) Tightening Torques LUBRICATION Name Torque in Nm Hub oil drainage cap 15 ÷ 17 Oil filter 4 ÷ 6 Oil pump cover screws 5 - 6 Oil pump screws 5 - 6 Pump control pulley screw 10 ÷...

  • Page 14: Assembly Clearances

    Characteristics CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead (transmis- 4 ÷ 6 sion-side half shaft) screws Oil filter on crankcase fitting 27 ÷ 33 Rear brake cam tightening screw 11 ÷ 13 Engine-crankcase coupling screws 11 ÷ 13 Pre-filter cap 24 ÷...
  • Page 15 Characteristics Cylinder - piston assy. Version 150 COUPLING BETWEEN (A ) PISTON AND CYLINDER (150) ERKE Name Initials Cylinder Piston Play on fitting Coupling 62.580 ÷ 62.587 62.533 ÷ 62.540 0.040 ÷ 0.054 Coupling 62.587 ÷ 62.594 62.540 ÷ 62.547 0.040 ÷...
  • Page 16 Characteristics Name Initials Cylinder Piston Play on fitting Coupling 1st in- 57.187 ÷ 57.194 57.140 ÷ 57.147 0.040 - 0.054 crease Coupling 1st in- 57.194 ÷ 57.201 57.147 ÷ 57.154 0.040 - 0.054 crease Coupling 1st in- 57.201 ÷ 57.208 57.154 ÷...

  • Page 17: Piston Rings

    Characteristics Piston rings SEALING RINGS (125) Name Description Dimensions Initials Quantity Compression ring 57 x 1 0.15 ÷ 0.30 Oil scraper ring 57x1 0.10 ÷ 0.30 Oil scraper ring 57x2.5 0.10 ÷ 0.35 Compression ring 57.2 x 1 0.15 ÷ 0.30 1st oversize Oil scraper ring 1st 57.2x1...
  • Page 18 Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side Flywheel-side half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Connecting rod 18 -0.10 -0.15 0.20 ÷...
  • Page 19 Characteristics Slot packing system - Provisionally fit the piston into the cylinder, without any base gasket. - Fit a dial gauge on the specific tool - Set the dial gauge to zero at a contrast plane with an average precharge, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.
  • Page 20 Characteristics SHIMMING SYSTEM (150) Specification Desc./Quantity Value measured 1 ÷ 1.1 Thickness 0.8 ± 0.05 Value measured 1.1 ÷ 1.3 Thickness 0.6 ± 0.05 Value measured 1.3 ÷ 1.4 Thickness 0.4 ± 0.05 Products TABLE OF RECOMMENDED PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 rear oil hub...

  • Page 21: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 22 Tooling TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15-mm bear- ings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor TOOL - 22...
  • Page 23 Tooling Stores code Description 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge TOOL - 23...
  • Page 24 Tooling Stores code Description 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cyl- inder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol TOOL - 24...
  • Page 25 Tooling Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 25...
  • Page 26 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25-mm guide TOOL - 26...
  • Page 27 Tooling Stores code Description 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor - Peak volt- age detection TOOL - 27...
  • Page 28 Tooling Stores code Description 020412Y 15 mm guide 020414Y 28-mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel-side oil seal 020426Y Piston fitting fork TOOL - 28...
  • Page 29 Tooling Stores code Description 020427Y Piston fitting band 020428Y Piston position check support 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driv- en pulley clutch TOOL - 29...
  • Page 30 Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission-side oil guard punch 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the ex- haust manifold TOOL - 30...

  • Page 31: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 32: Maintenance Chart

    Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change EVERY 3000 KM Action Engine oil - level check/ top-up AFTER 1000 KM Action Engine oil - replacement Hub oil - change Oil filter (net filter) - clean Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing...
  • Page 33 Maintenance Action Hub oil level - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Spark plug - replacement Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing Steering - adjustment...
  • Page 34 Maintenance (*) See instructions in «Idle speed adjustment» section AT 30000 KM, AT 42000 KM AND AT 66000 KM 125' Action Engine oil - replacement Hub oil level - check Spark plug electrode gap - check Air filter - clean Engine oil - change Oil filter (net filter) - clean Slide pads and variator rollers - check...

  • Page 35: Checking The Spark Advance

    Maintenance Action Engine oil - replacement Hub oil - change Spark plug - replacement Air filter - clean Engine oil - change Oil filter (net filter) - clean Valve clearance - adjustment Idle speed (*) - adjustment Throttle lever - adjustment Pads and variator rollers - replacement Driving belt - replacement Odometer gear - greasing...
  • Page 36 Maintenance - Operating on the flash bulb phase difference cal- ibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Read the advance degrees indicated by the stroboscopic light and compare them with those specified.
  • Page 37 Maintenance MAIN - 37...

  • Page 38: Braking System

    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 39: Headlight Adjustment

    Maintenance THE BRAKE FLUID IS HYGROSCOPIC, IN OTH- ER WORDS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEF- FICIENT. NEVER USE BRAKE LIQUID IN OPEN OR PAR- TIALLY USED CONTAINERS.
  • Page 40 Maintenance CO check - Remove the exhaust gases outlet cap on the ex- haust pipe - Using the supplied washer, install the exhaust gases collection kit fitting onto the pipe, as shown in the figure. - Correctly orientate the components as shown in the picture - Shut the gas outlet on the tool - Start the engine and let it warm up...
  • Page 41 Maintenance - Connect the Mitivac vacuum pump to the SAS control valve. - Start the vacuum pump up to a pressure of -0.6 ÷ -0.8 bar so to close the valve and cut off the SAS system. - Remove the exhaust gas collection kit cap and connect the analyzer adequately pre-heated.
  • Page 42 Maintenance SAS filters inspection and cleaning - Remove the shock absorber lower retainer from the engine. - Remove the retainer clamp indicated in the pho- tograph, the automatic starter cable harness and the carburettor to frame heater placed under the helmet compartment cover.
  • Page 43 Maintenance - Remove the 4 flywheel cover screws indicated in the photograph and remove the flywheel cover. - Remove the filter indicated in the photograph - Check that the gasket is in good conditions - Check the SAS filter housing for dents or defor- mations - Clean the SAS filter carefully.

  • Page 44: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 45: Poor Performance

    Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Air filter blocked or dirty. Dismantle the sponge, wash with water and sham- poo, then soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.

  • Page 46: Starting Difficulties

    Troubleshooting Starting difficulties DIFFICULTY STARTING UP Possible Cause Operation Battery flat Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit...

  • Page 47: Excessive Fuel Consumption

    Troubleshooting Insufficient lubrication pressure POOR LUBRICATION PRESSURE Possible Cause Operation By-Pass remains open Check the By-Pass and replace if required. Care- fully clean the By-Pass area. Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low...

  • Page 48: Brakes Overheating

    Troubleshooting Possible Cause Operation Loose nozzles Check the maximum and minimum nozzles are adequately fixed in their fittings Incorrect float level Restore the level in the tank by bending on the float the thrusting reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted.
  • Page 49 Troubleshooting Possible Cause Operation Defective piston sliding Check calliper and replace any damaged part. Electrical system 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 50: Noisy Suspension

    Troubleshooting Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Excessive steering backlash Check the tightening of the top ring nut. If irregu- larities 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 51: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 52 Electrical system Legend: 1. Front L.H. turn signal light 2. Immobiliser antenna 3. Electronic ignition device with choke and turn signal controls 4. Horn button 5. Turn signal switch 6. Headlight switch 7. Stop switch on rear brake 8. Double-filament bulb 12V - 55/60W 9.
  • Page 53 Electrical system 13. Low-fuel warning light 14. Turn signal warning light (R.H.) 15. Dashboard light bulbs 16. Headlamp warning light 17. Odo/speedometer with warning lights and gauges - Red socket light bulbs 2W; black socket light bulbs 1.2W 18. Headlight 19.

  • Page 54: Electrical System Installation

    Electrical system Mr = Brown N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Purple V = Green VN = Green-Black BN = White-Black BBl = White-Blue GV = Yellow-Green Ar = Orange Az = Light Blue GrBl = Gray-Blue...

  • Page 55: Front Side

    Electrical system Front side FRONT INSTALLATION 1 Specification Desc./Quantity Strap Insert the strap through the hole in the chas- Zip tie Fixing Fold the chassis strap over the cables ELE SYS - 55...
  • Page 56 Electrical system FRONT INSTALLATION Specification Desc./Quantity Front R.H. turn signal light Fuse holder box Front L.H. turn signal light Light remote control switch Ignition key-switch Control device ignition Immobiliser diagnostic outlet ELE SYS - 56...
  • Page 57 Electrical system Specification Desc./Quantity Zip tie Horn FRONT INSTALLATION 2 Specification Desc./Quantity Zip tie ELE SYS - 57...

  • Page 58: Back Side

    Electrical system Back side REAR INSTALLATION Specification Desc./Quantity Cable harness fairlead Breather tube Heater conductors and automatic choke pro- tective sheath Voltage regulator HV coil Earth node Starter remote control License plate light connector ELE SYS - 58...
  • Page 59 Electrical system REAR INSTALLATION 1 Specification Desc./Quantity H.T. Cable Zip tie To the automatic choke device To the heater Rear R.H. turn signal light Taillight Rear L.H. turn signal light ELE SYS - 59...
  • Page 60 Electrical system REAR INSTALLATION 2 Specification Desc./Quantity Zip tie Starter motor earth Starter motor positive outlet Flywheel connection Conceptual diagrams ELE SYS - 60...
  • Page 61 Electrical system Ignition IGNITION Specification Desc./Quantity electronic control unit Magneto flywheel Pick - up HV coil Spark plug Voltage regulator ELE SYS - 61...
  • Page 62 Electrical system Headlights and automatic starter section LIGHTS AND AUTOMATIC STARTER Specification Desc./Quantity electronic control unit Carburettor heater Automatic starter Key switch Main fusible Battery 12V-9Ah Headlamp relay Light switch High-beam fuse 7,5A Low-beam and dashboard lights fuse 7,5A Low-beam light bulb 12V - 55W High-beam light bulb 12V-55W...
  • Page 63 Electrical system Battery recharge and starting BATTERY CHARGER AND STARTING Specification Desc./Quantity Magneto flywheel Voltage regulator Pick - up Main fusible Battery 12V-9Ah Starter relay Starter motor Start up button Front and rear brake light button Brake light filament 12V-21W Fuse 7.5 A Key switch...
  • Page 64 Electrical system Level indicators and enable signals section CONSENSUSES AND LEVEL INDICATORS Specification Desc./Quantity electronic control unit Battery 12V-9Ah Main fusible Key switch Engine oil pressure sensor Low oil pressure warning light 12V - 1,2W Reserve fuel light 12V-1,2W Fuel gauge Fuel level sender Fuse 7.5 A...

  • Page 65: Turn Signal Lights

    Electrical system Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity electronic control unit Indicators switch 4 Turn indicator bulbs 12V-10W Turn signal warning light bulbs 12V - 2W Main fusible Battery 12V-9Ah Horn Fuse 7.5 A Key switch Horn button ELE SYS - 65...

  • Page 66: Pin Connector

    Electrical system Instruments and warning lights control board 4 PIN CONNECTOR Specification Desc./Quantity Ground lead (-) High-beam warning light Left turn indicator Engine oil warning light 5 PIN CONNECTOR Specification Desc./Quantity Instrument panel lighting and headlamp warning light Right turn indicator Low-fuel warning light + permanent power supply Fuel gauge...
  • Page 67 Electrical system Immobiliser The electric ignition system is fed with direct cur- rent and is protected by an anti-theft immobilizer integrated to the control unit. The ignition system consists of: - electronic control unit - immobilizer aerial - master and service keys with built-in transponder - HV coil - diagnosis LED The diagnosis LED also works as a blinking light...
  • Page 68 Electrical system Detach the connector from the ECU and check the following: - Presence of battery potential difference between terminal 4 (Red/Blue) and earth - Presence of battery potential difference between terminals 4 (Red/Blue) and 8 (black), as shown in the figure.

  • Page 69: Diagnostic Codes

    Electrical system Once the control unit has been programmed, the control unit is inseparably matched with the MAS- TER key transponder. This matching allows programming further service keys in case of loss, replacement, etc. Each new time new data is programmed the previously stor- ed one is deleted.

  • Page 70: Ignition Circuit

    Electrical system If it does not work, replace the aerial. If no faults are found, replace the control unit. CAUTION BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY. Specific tooling 020331Y Digital multimeter Electric characteristic...
  • Page 71 Electrical system To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient. No spark plug When noticing no spark plug proceded as follows: - Pick-Up inspection. Detach the ECU connector and check for continu- ity between terminals 2 (Green) and 8 (Black).
  • Page 72 Electrical system 020409Y Multimeter adaptor - Peak voltage detection Electric characteristic High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm - Pick-Up Detach the ECU connector and connect the posi- tive terminal to connector no. 2 and the negative terminal to connector no.

  • Page 73: Stator Check

    Electrical system Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth and to the battery positive passing through the 15A safety fuse.
  • Page 74 Electrical system Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. The voltage should not exceed 15.2 Volt. In case higher voltages are detected, replace the regulator. In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.
  • Page 75 Electrical system with the key switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the key switch. If battery potential is found, repeat the inspection from the connector to the ECU. After detaching the choke device, start the engine and, while at idle, check for tension connecting the positive terminal of the multimetre to terminal 5...
  • Page 76 Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.
  • Page 77 Electrical system Commissioning dry-charged batteries : 1) - Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 Be at a minimum tem- perature of 15°C until the upper level is reached.
  • Page 78 Electrical system The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle electrical system: the battery works overcharged and is subject to quick wear. 2)Load status check After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure).

  • Page 79: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 80 Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Unscrew the 2 screws fixing the muffler to the housing; then remove the whole muffler paying at- tention to the interference between its supporting bracket and the cooling cover.
  • Page 81 Engine from vehicle - Remove the fuel supply pipe from the carburettor - Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph - Remove the flywheel wiring connector, the earth terminal and the starter motor positive cable indi- cated in the figure - Remove the clamp retaining the starter wiring and the heater indicated in the figure...
  • Page 82 Engine from vehicle - Remove the protection sheath indicated in the figure and disconnect the automatic starter and carburettor heater connections - Unscrew the engine pin-swinging arm nut on the right-hand side of the vehicle and slide off the pin on the left hand side - Support the vehicle adequately (with a jack) and remove the shock absorber lower clamping.
  • Page 83 INDEX OF TOPICS NGINE...

  • Page 84: Automatic Transmission

    Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the rear plastic cover first by inserting a screwdriver in the corresponding slotted holes.

  • Page 85: Removing The Driven Pulley Shaft Bearing

    Engine Air duct - Unscrew the Torx screws fixing the air manifold bulkhead and remove the bulkhead. - Remove the 3 screws, then take out the manifold as well as the filter. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Use the specific tools to remove the bearing from the crankcase.

  • Page 86: Removing The Driven Pulley

    Engine Refitting the driven pulley shaft bearing - Heat up the crankcase inside with the hot air gun. - Insert the bearing in its housing, refit the Seeger ring. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING. Specific tooling 020151Y Air heater 020376Y Adaptor handle...

  • Page 87: Removing The Clutch

    Engine Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inner diameter 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft assembly on the support to check the crankshaft alignment.
  • Page 88 Engine - Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. After- wards make the support screw make contact with a minimum force. - Using the specific wrench, inserted 46 mm from the side, remove the clutch central locking nut.
  • Page 89 Engine Pin retaining collar - Remove the collar with the aid of 2 screwdrivers. - Remove the 3 guide pins and the movable half- pulley. Removing the driven half-pulley bearing - Remove the retaining ring using two flat blade screwdrivers. - Using a hammer and pin, knock the ball bearing out as shown in the figure.
  • Page 90 Engine Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bush- ing. Characteristic Minimum diameter permitted Ø 40.96 mm Standard diameter Ø 40.965 mm Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings.

  • Page 91: Refitting The Driven Pulley

    Engine - To assemble the new ball bearing insert it com- pletely down in its housing with the specific punch and finally assemble the Seeger ring. Specific tooling 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020439Y 17 mm guide Refitting the driven pulley - Check that the faying surfaces between the 2 half-pulleys and the belt do not show any signs of...
  • Page 92 Engine Inspecting the clutch spring - Measure the unloaded length of the spring of the movable driven half-pulley. Characteristic Standard length: 106 mm Refitting the clutch - Check the thickness of the clutch mass friction material. -The masses must not show traces of lubricants; otherwise, check the driven pulley unit.
  • Page 93 Engine - Insert the driving belt into the pulley unit accord- ing to their direction of rotation. - Insert the pulley unit with the belt into the tool. - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut.
  • Page 94 Engine Refitting the driven pulley - Reassemble the clutch bell and spacer. Drive-belt During the wear checks foreseen in the scheduled maintenance services at 6,000 km; 18,000 km; etc., check that the rim bottom of the toothing does not show signs of incisions or cracking (see figure): The rim bottom of the tooth must not have incisions or cracking;...

  • Page 95: Removing The Driving Pulley

    Engine Removing the driving pulley - Lock the driving pulley with the specific tool as shown in the figure. - Disassemble the central nut and the Belleville washer, remove the drive and the 2 washers. - Remove the stationary half pulley and the steel washer.
  • Page 96 Engine - Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves. Refitting the driving pulley - Reassemble the parts of the unit (internal lining, fixed half-pulley, external lining, drive and nut), spread threadlock on the thread and screw the nut...
  • Page 97 Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
  • Page 98 Engine Removing the wheel axle Remove the intermediate gear and the complete hub cover. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
  • Page 99 Engine With the appropriate tools, remove the oil seal as shown in the figure. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven pulley.
  • Page 100 Engine Inspecting the hub cover - Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the brake camshaft. - If faults are found, replace the hub cover. Refitting the driven pulley shaft bearing - Heat up the parts using the specific heat gun Specific tooling 020150Y Air heater support...
  • Page 101 Engine • Assemble the Seeger ring. • Assemble the oil seal flush with the in- ternal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub. Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm...

  • Page 102: Flywheel Cover

    Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Fit the gearbox cover, making sure the breather pipe is in the correct position. - Screw the 7 screws to the specified torque, po- sitioning the support plate of the pipe in the posi- tion shown in the figure.

  • Page 103: Cooling Fan

    Engine IF THE FLYWHEEL HOUSING IS NOT RE- MOVED, IT IS ALSO NECESSARY TO REMOVE THE TWO KNOB SCREWS. On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.4 mm to 1.5 mm.
  • Page 104 Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. - Place the cable harness as shown in the figure. N.B. THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN THE UPPER SCREW AND THE REF- ERENCE PIN AS SHOWN IN THE DETAIL DRAWING.
  • Page 105 Engine Inspecting the flywheel components - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate. Refitting the flywheel magneto - Fit the flywheel being careful to insert the key properly. - Lock the flywheel nut to the prescribed torque - Check that the Pick-Up air gap is between 0.34 ÷...
  • Page 106 Engine Removing the timing system drive - Remove the parts listed below first: transmission cover, belt driving pulley, oil pump pulley cover and pinion separator washer. - Remove the tappet cover. - Remove the central screw fastener and the au- tomatic valve-lifter retaining cover, as shown in the figure.

  • Page 107: Removing The Cam Shaft

    Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic wash- N.B.

  • Page 108: Removing The Valves

    Engine MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool - Remove the oil seals with the appropriate tool.

  • Page 109: Inspecting The Small End

    Engine - Remove the two stop rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston. N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL. Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer.
  • Page 110 Engine - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASURE- MENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PIS- TON. Characteristic Piston pin bore - standard diameter Ø...

  • Page 111: Inspecting The Piston

    Engine - The pistons are oversized due to cylinder rectifi- cation and are subdivided into three categories 1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They are also classified into 4 categories A-A, B-B, C- C, D-D. Inspecting the piston - Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram.
  • Page 112 Engine - With the opening in position indicated on the tool, take stop ring in the closed position using the punch. - Fit the wrist pin stop using the plug as shown in the figure N.B. THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.

  • Page 113: Inspecting The Cylinder Head

    Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFUL- LY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
  • Page 114 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft drive pulley, the chain assembly and the sprocket wheel are not worn. - If sings of wear are found, replace the parts. if the chain, pinion or pulley are worn, replace the whole assembly.
  • Page 115 Engine Characteristic Standard drainage guide diameter 5.012 mm Standard inlet guide diameter 5.012 mm - If the width of the impression on the valve seat or the diameter of the valve guide exceed the speci- fied limits, replace the cylinder head. - Check width of the impression on the valve seat «V»...
  • Page 116 Engine - Check that there are no signs of wear on the contact surface with the articulated register termi- nal. - If the sealing surface on the valves is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.

  • Page 117: Inspecting The Cam Shaft

    Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. - Check the length clearance of the springs. Characteristic Valve spring length 33.9 ÷ 34.4 mm Refitting the valves - Lubricate the valve guides with engine oil.
  • Page 118 Engine Minimum admitted diameter bearing A Ø: 32.440 mm Minimum admitted diameter bearing B Ø: 19.950 mm Inlet cam height 27.512 mm Outlet cam height 27.212 mm - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new...
  • Page 119 Engine In case of anomalies, replace the damaged com- ponents. Characteristic Minimum diameter permitted Ø 11.970 mm Maximum diameter admitted Ø 12.030 mm Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder. -Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
  • Page 120 Engine - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que. Locking torques (N*m) Locking torque 4 ÷ 6 - Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase.
  • Page 121 Engine - Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed tor- que. Locking torques (N*m) Locking torque 12 - 14 - Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque.

  • Page 122: Crankcase - Crankshaft

    Engine Locking torque 3 ÷ 4 - Fit the inlet manifold and lock the 2 screws to the specified torque. - Fit the carburettor onto the inlet manifold and lock the clamp N.B. FIT THE CARBURETTOR THROUGH THE SUP- PLEMENT ON THE MANIFOLD. Locking torques (N*m) Locking torque 11 ÷...
  • Page 123 Engine - 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 specific tool dial gauge. Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Standard clearance 0.15 ÷...
  • Page 124 Engine - Remove the oil guard on the flywheel side. - Remove the oil filter fitting shown in the diagram - Check the axial clearance on the connecting rod. Characteristic Standard clearance 0.20 ÷ 0.50 mm - Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial free-play are not scored and measure the width of the crank- shaft between these surfaces, as shown in the...
  • Page 125 Engine Distance between the shoulders 55.67 ÷ 55.85 mm - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart below.
  • Page 126 Engine - A wrong installation of a cap can seriously affect the bushing lubrication pressure. N.B. THE MAIN BEARINGS ARE NOT GRINDABLE Specific tooling 020074Y Support base for checking crankshaft alignment Characteristic Off-line maximum admitted A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm Inspecting the crankcase halves...
  • Page 127 Engine - On the flywheel side crankcase half, take partic- ular care cleaning the oil ducts for the main bush- ings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the fly- wheel side oil seal.

  • Page 128: Main Bearings

    Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
  • Page 129 Engine Specification Desc./Quantity Yellow Green Refitting the crankcase halves - Fit the internal bulkhead by locking the two screws to the prescribed torque. Locking torques (N*m) Locking torque 4 ÷ 6 - Fit the oil filter joint and tighten it to the prescribed torque.
  • Page 130 Engine Locking torques (N*m) Locking torque 11 ÷ 13 - Lubricate the flywheel oil seal. - Use the appropriate tool to assemble the oil seal. - Fit a new O-ring on the pre-filter and lubricate it. - Insert the pre-filter on the engine with its corre- sponding cover to the specific torque.
  • Page 131 Engine Conceptual diagrams ENG - 131...

  • Page 132: Oil Pressure Check

    Engine Oil pressure check - After removing the cover protections as descri- bed in the "Flywheel" chapter, disconnect the elec- trical connexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure is between 0.5 ÷...
  • Page 133 Engine Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided. - Screw the threaded bar onto the base of the tool and extract the oil guard.
  • Page 134 Engine - Preassemble the oil seal 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 CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS.

  • Page 135: Oil Pump

    Engine - Use the nut to move the base of the tool until you can see end of the oil seal driving stroke - Remove all of the tool components following the procedure in reverse order CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
  • Page 136 Engine - Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion. - Remove the oil pump acting on the 2 retainers as shown in the figure. - Remove the oil pump seal.
  • Page 137 Engine Measure the distance between the outer rotor and the pump body; see figure. Characteristic Admissible limit clearance: 0.20 mm Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure. Characteristic Limit values admitted: 0.09 mm Refitting - Check there are no signs of wear on the oil pump...
  • Page 138 Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete drive pulley assembly with belt and the sprocket wheel, as described in the Transmis- sion chapter. - Drain the oil from the sump as described above. - Remove the 7 screws indicated in the figure and the 2 rear brake transmission fixing brackets.

  • Page 139: Fuel Supply

    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 sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.

  • Page 140: Removing The Carburettor

    Engine N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE.. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUTLET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PUR- POSE OF ENHANCING THE SUCTION PULSA- TION AND THEREBY GUARANTEE A CON-...
  • Page 141 Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
  • Page 142 Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure. ENG - 142...
  • Page 143 Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
  • Page 144 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 144...
  • Page 145 Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT. -Remove the minimum nozzle. - Remove the minimum flow set screw and the spring.
  • Page 146 Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
  • Page 147 Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear. - Check that the plunger seat does not show abnormal wear. - Replace the carburettor in case of irregularities.
  • Page 148 Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
  • Page 149 Engine - Wash and blow the flow screw properly. - Check that screw is not deformed and/or rusty. - Assemble the spring on the screw. - Screw the flow screw on the carburettor body. - The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position.
  • Page 150 Engine • Insert a transparent rubber pipe to the bleeding intake of the fuel tank. • Keep the pipe up so that the ends are higher than the venturi pipe. • Unscrew the bleed screw and stabilise the petrol level, then measure as shown in the dia- gram.
  • Page 151 Engine Inspecting the valve and needle - Check that the tapered pin of the vacuum valve does not show wear. - Check that the depression valve does not show threads on the external surfaces. - Check that the vacuum intake hole is not clogged. - Check that the diaphragm is not damaged or has hardened, otherwise replacement the whole valve.
  • Page 152 Engine - Wash and blow dry the filter sponge of the am- bient pressure intake. - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. ENG - 152...
  • Page 153 Engine Inspecting the automatic choke device - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the piston sealing gasket is not de- formed.

  • Page 154: Adjusting The Idle

    Engine Check the automatic starter: Kehin: Protrusion value XX ÷ XX mm at approx. 20°C Check the automatic starter: Kehin maximum protrusion XXX ÷ XXX mm Check the automatic starter: Keihin maximum time 5 min Adjusting the idle - The engine does not require frequent adjustment of the idle, however it is important that this adjust- ment be made in complete compliance with a few rules.
  • Page 155 Engine â 4.5%, by loosening the screw the CO value in- creases (rich mixture) by tightening the CO value decreases (thin mixture). - If correction of the flow screw position leads to an increase in speed, adjust the revolutions again and if necessary the flow screw until stabilised values are achieved.
  • Page 156 Engine READING OF GASES AND THE CORRECT GAS CAPACITY. FAILURE TO RESPECT THESE REGULATIONS RESULTS IN INACCU- RATE READINGS. N.B. THE WASTED SPARK IGNITION SYSTEM OF- FERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED. CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 ÷...

  • Page 157: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 158: Removing The Front Wheel

    Suspensions Sospensioni anteriore This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the wheel axle locking nut. - Remove the wheel axle and the wheel. - Upon removal take care not to damage the sen- sor that detects movement in the odometer.

  • Page 159: Refitting The Front Wheel

    Suspensions - Check that the bearings do not show flaws or jamming. If there is, replace it. - Check that the internal spacer does not show ab- normal wear. If there is, replace it. - With a hot air gun heat the seat of the bearing on the brake calliper side - With an appropriate tool remove the bearing on the brake disk side...

  • Page 160: Front Fork

    Suspensions Handlebar Removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and discon- necting the electrical terminals, remove the termi- nal fixing the handlebar to the steering. - Check all components and replace faulty parts. N.B.
  • Page 161 Suspensions - Remove the upper screw (2). - Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for forks). - Refit all components. Locking torques (N*m) Upper screw tightening torque 20 to 25 Nm Lower screw tightening torque: 20 to 25 Nm Refitting When fitting the fork, lubricate with the steering bearing tracks with the recommended grease.

  • Page 162: Steering Column

    Suspensions Steering column Refitting Upper and lower seat on chassis Lower and upper seating on the chassis OWER AND UPPER SEATING ON THE CHASSIS Titolo Durata/ Testo Indirizzo Valore Breve (< Immagine 4000 car.) Lower and upper seating on the chas- Steering bearing Steering bearing upper seat Removal...

  • Page 163: Removing The Rear Wheel

    Suspensions Rear 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 164: Centre-Stand

    Suspensions Shock absorber/engine pin torque 33 to 41 N·m Shock absorber/frame nut torque 20 to 25 Centre-stand Complete centre stand replacement - Undo the screw marked in the figure. - When refitting, secure to the prescribed torque. Locking torques (N*m) Centre stand screw 32 ÷...
  • Page 165 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 166: Front Brake Calliper

    Braking system Front brake calliper Removal - Inspect the condition of the hoses, packing and joint. In the event of fluid leaks from the calliper, this must be replaced. - Detach the oil brake pipe from the calliper; pour the fluid inside a container. - Remove the clamps shown in the figure.
  • Page 167 Braking system 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corre- sponding screws (1);...

  • Page 168: Front Brake Disc

    Braking system Refitting - When refitting, tighten the nuts to the prescribed torque. - Bleed the system. N.B. WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS. Locking torques (N*m) Oil bleed screw 7 ÷ 10 Calliper tightening screw 24 ÷ 27 Brake fluid tube- calliper fitting 19 ÷ 24 See also Front Front brake disc...

  • Page 169: Disc Inspection

    Braking system Disc Inspection - Remove the wheel and check for unevenness of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and re- peat the check. - If the problem persists, check and replace the wheel rim if necessary.
  • Page 170 Braking system Locking torques (N*m) Screw tightening calliper to the support 20 ÷ 25 Pad fastening pin 19.6 ÷ 24.5 Fill 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.
  • Page 171 Braking system UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/ OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY. CAUTION WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER.
  • Page 172 Braking system Removal - Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac- tuate the brake lever until no more fluid flows out. -Remove the oil pump from the handlebar; remove the brake lever and then remove the wheel cylin- der.

  • Page 173: Rear Drum Brake

    Braking system 2. Tank cover. 3. Diaphragm. 4. Bellows. 5. Sealing ring. 6. Piston. 7. Gasket. 8. Spring. Rear drum brake Once the muffler and the wheel have been re- moved, follow these steps: 1.Remove the shoe spring using the specific span- ner.
  • Page 174 INDEX OF TOPICS CHAS HASSIS...
  • Page 175 Chassis Removing the ignition key-switch when on *off* • Remove the shield back plate • Push the lock body until the stop spring does not show grooves. • Keep the lock body blocked with a screwdriver and remove the spring with a pair of pliers. •...

  • Page 176: Air Filter

    Chassis Air filter • Unscrew the 7 cover screws and remove the cover to reach the filter sponge. • To disassemble the filter housing, unscrew the 2 bottom screws and disconnect the manifold con- nections, the carburettor and the external air in- take.

  • Page 177: Fuel Tank

    Chassis Helmet bay - Remove the side fairings - Remove the helmet compartment by undoing the 4 screws indicated in the figure Fuel tank - Remove the side fairings - Remove the rear mudguard - Remove the crews shown in the photograph - Remove the shock absorber upper clamping in order to create the necessary space to take out the tank.
  • Page 178 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 179 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 Front wheel axle nut Wheel hub nut Frame - swinging arm bolt * Swinging arm bolt - Engine...
  • Page 180 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. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.

  • Page 181: Static Test

    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. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

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