Gilera 633499 Workshop Manual
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Gilera 633499 Workshop Manual

Gilera 633499 Workshop Manual

Runner purejet
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WORKSHOP MANUAL
633499
Runner Purejet

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  • Page 1 WORKSHOP MANUAL 633499 Runner Purejet...
  • Page 2 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS INJ PJ PURE JET INJECTION BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    Runner Purejet Characteristics Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...
  • Page 9 Runner Purejet Characteristics Dimensions and mass DIMENSIONS Specification Desc./Quantity Total vacuum weight 93 kg. gear sequence Max width 720 mm. Max length 1800 mm. Wheelbase 1290 mm. Seat height 830 mm. Engine ENGINE Specification Desc./Quantity Type single-cylinder, two-stroke Number of cylinders Bore Stroke 39.3 mm...

  • Page 10: Electrical System

    Runner Purejet Characteristics Capacities CAPACITY Specification Desc./Quantity Fuel tank (including reserve ~3 l) ~ 12 l Oil mixer tank (indicative value) ~1,8 l Rear hub ~75 cc Cooling circuit ~ 0.90 l Electrical system ELECTRICS Specification Desc./Quantity Type of ignition Electronic ignition with H.V.

  • Page 11: Wheels And Tyres

    Runner Purejet Characteristics Wheels and tyres WHEELS AND TIRES Specification Desc./Quantity Front tire dimension 120/70-12" Rear tire dimension 130/70-12" Pressione pneumatici Ruota anteriore: 1,6 bar / Ruota posteriore: 1,8 bar Circles 3,50 x 12" (light alloy) N.B. CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU- LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES Tightening Torques COPPIE DI SERRAGGIO IN N·...
  • Page 12 Runner Purejet Characteristics Name Torque in Nm Shock-absorber - frame nut * 20 ÷ 25 Shock-absorber - engine bolt * 33 ÷ 41 Wheel axle pin* 100 ÷ 125 Stand pin 18.5 ÷ 19 Stand screws 18.5 ÷ 19 *: Bloccaggi di sicurezza. SOSPENSIONE ANTERIORE Name Torque in Nm...

  • Page 13: Assembly Clearances

    Runner Purejet Characteristics Name Torque in Nm Oil drain rear hub screw 3 ÷ 5 Clutch nut 55 ÷ 60 Mixer strip screw 3 ÷ 4 Ignition spark plug 11 ÷ 14 Head union screw 3 ÷ 4 Flywheel cover screw 1 ÷...
  • Page 14 Runner Purejet Characteristics Piston rings ANELLI DI TENUTA Name Description Dimensions Initials Quantity Anello di tenuta 0,10 ÷ 0,25 Anello di tenuta 1° 40,2 0,10 ÷ 0,25 Magg. Anello di tenuta 2° 40,4 0,10 ÷ 0,25 Magg. Crankcase - crankshaft - connecting rod PISTON - TEST PROBE Name Descrip...
  • Page 15 Runner Purejet Characteristics Name Description Dimensions Initials Quantity Shoulder washer 0.5 ±0.03 0.25 ÷ 0.50 Semi-shaft, trans. 13.75 +0.04 0 0.25 ÷ 0.50 side Semi-shaft, fly- 13.75 +0.04 0 0.25 ÷ 0.50 wheel side Spacer tool 40.64 0.25 ÷ 0.50 Casing 11.8 0 -0.35 0.20 ÷...
  • Page 16 Runner Purejet Characteristics Name Descrip Dimens Initials Quantit tion ions Roller Cat. 2 Ø 2.5 -0.002 casing -0.004 Roller Cat. 3 Ø 2.5 -0.004 casing -0.006 Roller Cat. 1 Ø 2.5 -0.001 casing Optional -0.003 Roller Cat. 2 Ø 2.5 -0.003 casing Optional...
  • Page 17 Runner Purejet Characteristics Product Description Specifications AGIP CITY HI TEC 4T Oil for flexible transmission lubri- Synthetic oil that passes SAE cation (acceleration control, mix- 5W-40, API SL, ACEA A3, JASO er and odometer) MA specifications AGIP CITY HI TEC 4T Oil for air filter sponge Synthetic oil that passes SAE 5W-40, API SL, ACEA A3, JASO...
  • Page 18 Runner Purejet Characteristics CHAR - 12...
  • Page 19 INDEX OF TOPICS TOOL OOLING...
  • Page 20 Runner Purejet Tooling TOOLING Stores code Description 001330Y Tool for fitting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm ø bear- ings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø...
  • Page 21 Runner Purejet Tooling Stores code Description 001467Y017 Bell for bearings, outside Ø 39 001467Y021 Extraction pliers for ø 11 mm bearings 001467Y029 Bell for bearings, O.D. 38 mm 002465Y Pliers for circlips 004499Y Camshaft bearing extractor TOOL - 3...
  • Page 22 Runner Purejet Tooling Stores code Description 004499Y007 Half rings 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank- shaft alignment 020080Y Punch for removing 12-mm bear-...
  • Page 23 Runner Purejet Tooling Stores code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020166Y Pin lock fitting tool 020168Y Water seal punch mount on half- crankcase TOOL - 5...
  • Page 24 Runner Purejet Tooling Stores code Description 020169Y Water pump crankshaft fitting and removal spanner 020170Y Water pump/mixer command gear extractor 020171Y Punch for driven pulley roller bearing 020209Y Spring hook 020265Y Bearing fitting base TOOL - 6...
  • Page 25 Runner Purejet Tooling Stores code Description 020272Y Piston position check tool 020325Y Brake-shoe spring calliper 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol 020331Y Digital multimeter TOOL - 7...
  • Page 26 Runner Purejet Tooling Stores code Description 020332Y Digital rev counter 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020357Y 32 x 35 mm adaptor 020358Y 37x40-mm adaptor 020359Y 42x47-mm adaptor 020362Y 12-mm guide TOOL - 8...
  • Page 27 Runner Purejet Tooling Stores code Description 020363Y 20 mm guide 020409Y Multimeter adaptor - Peak volt- age detection 020376Y Adaptor handle 020412Y 15 mm guide 020439Y 17 mm guide 020444Y Test probe removal / fitting tool TOOL - 9...
  • Page 28 Runner Purejet Tooling Stores code Description 020456Y Ø 24 mm adaptor 020451Y Start-up crown lock 020452Y Tube for removing and refitting the driven pulley shaft 020460Y Scooter diagnosis and tester 020481Y Control unit interface wiring TOOL - 10...
  • Page 29 Runner Purejet Tooling Stores code Description 020565Y Flywheel lock calliper spanner 020469Y Reprogramming kit for scooter diagnosis tester 020614Y Diagnostic tester programming software 020615Y Carbon dam ring fitting kit 020616Y Fuel pressure control kit 020617Y Air pressure check kit TOOL - 11...
  • Page 30 Runner Purejet Tooling Stores code Description 020620Y Water pump impeller stop 020621Y HV cable extraction adaptor TOOL - 12...
  • Page 31 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 32: Maintenance Chart

    Runner Purejet Maintenance Purejet engines use a very lean air-petrol mixture when running at idle, with its effective percentage varying as a function of the engine temperature and power absorption. The throttle body supplies large amounts of air and the idle speed is kept at 2,000 rpm by adequately leaning down the mixture through the adjustment of the fuel injection timing.
  • Page 33 Runner Purejet Maintenance Action Oil mixer/throttle linkage - adjustment Variator rollers- Check wear Steering - adjustment Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Coolant level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrics - Check...
  • Page 34 Runner Purejet Maintenance Action Vehicle and brake test - road test AT 30.000 KM Action Hub oil level - Check / Replace Spark plug - replacement Fuel filter - replacement Air filter - clean Transmission gas mixer- adjust Driving belt - replacement Variator rollers- Check wear Steering - adjustment Brake control levers - greasing...

  • Page 35: Spark Plug

    Runner Purejet Maintenance Spark plug We inform you that, in order to avoid water infiltra- tions through the spark plug cap, the following modifications have been introduced: 1. The following parts have been discontinued: a) Spark plug cap b) Spark plug protective collar 2.

  • Page 36: Air Filter

    Runner Purejet Maintenance Replacement - Remove the oil charging cap. - Unscrew the oil drain plug "B" and allow the oil to flow out completely. - Rescrew the drain plug "B" and refill the engine with oil until it touches the full hole (apporx. 75cc.). - The level must correspond to the second notch starting from the bottom as shown in the picture.

  • Page 37: Fuel Filter

    Runner Purejet Maintenance - Impregnate with fuel mixture of 50% fuel and oil. CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER. Recommended products AGIP CITY HI TEC 4T Oil for air filter sponge Synthetic oil that passes SAE 5W-40, API SL, ACEA A3, JASO MA specifications Fuel filter To access the fuel filter remove the...
  • Page 38 Runner Purejet Maintenance Grease the ends of the cable. Transmission adjustment Set the command cables: Mix cable: see the following procedure "Mixer Timing". Gas cable: adjust so there is no play in the sheathes. Splitter command cable: adjust so there is no play in the gas knob. All transmissions must be regulated so there is no play in the sheathes.

  • Page 39: Cooling System

    Runner Purejet Maintenance Cooling system Level check - Remove the front grille - Check that the coolant level is between the min and max reference marks. Top up with recommended coolant, if necessary. Recommended products AGIP PERMANENT PLUS Coolant Monoethylene glycol antifreeze fluid, CUNA NC 956-16 See also Legshield...
  • Page 40 Runner Purejet Maintenance MAIN - 10...
  • Page 41 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 42: Engine Overheating

    Runner Purejet Troubleshooting Engine Engine overheating ENGINE OVERHEATING Possible Cause Operation No coolant in the cooling circuit Restore the level Incorrect air bleeding Repeat the operation Thermostat remains closed Replace Fluid leak in the radiator Replace the radiator Loss of fluid from the system Servicing the system Coolant leaks from crankcase draining hole Replace coolant sealing ring on half-crankcase...
  • Page 43 Runner Purejet Troubleshooting Possible Cause Operation Check that the front brake calliper moves in axis with the disc. Brake disc slack or distorted Check the locking of the brake disc screws; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc.

  • Page 44: Noisy Suspension

    Runner Purejet Troubleshooting Possible Cause Operation Turn indicators not working Check the turn indicator device and wiring. Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightness of the upper ring-nut. If irreg- ularities continue to appear in rotating the steering even after making the adjustments, check the housings where the ball bearings rotate: replace if not fitted.
  • Page 45 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 46 Runner Purejet Electrical system ELECRTRICS Specification Desc./Quantity Instrument panel Headlight assembly Stop switch on front brake Plug with contacts Starter button Right front turn indicator Ignition key-switch Fuel level sender Voltage regulator Coil Spark plug Fuel injector Air injector Water temperature sensor Throttle body pos.
  • Page 47 Runner Purejet Electrical system Specification Desc./Quantity Starter motor 15A fuse Diagnostics outlet Battery Lampada per lampeggiatori Stop light bulb Direction indicator bulb Oil mix warning light com. Start-up relay Electronic control unit Resistance 27Ω Fuel pump Horn 7,5A fuse Turn signal switch Left front turn indicator Horn button Commutatore lampeggiatori...
  • Page 48 Runner Purejet Electrical system IGNITION SECTION Specification Desc./Quantity Battery 12V - 9Ah Fuse Key switch contacts Voltage regulator 15A fuse HV coil Ignition spark plug Flywheel magneto Pick - up Headlights and automatic starter section HEADLIGHTS AND TURN INDICATORS Specification Desc./Quantity Voltage regulator Flywheel magneto...
  • Page 49 Runner Purejet Electrical system Specification Desc./Quantity Rear positioning bulbs 12V 5W Service light warning light 12V-12W 3 bulbs for lighting instrument 12V 1,2W Light switch Low beam bulb 12V-35W High beam bulb 12V-55W High-beam warning light 12V - 1.2W Fuse 7,5A 7.5A Key switch contacts...
  • Page 50 Runner Purejet Electrical system Specification Desc./Quantity Starter button Brake light filament 12V-21W Front brake stop light switch Rear stop light switch Battery 12V - 9Ah Fuse Key switch contacts Low-oil warning light switch Level indicators and enable signals section LEVEL INDICATORS AND HORN SCHEME Specification Desc./Quantity Water temperature sensor...
  • Page 51 Runner Purejet Electrical system Specification Desc./Quantity Fuel indicator Fuel level sending unit Turn indicator device com. Oil warning light Oil mix warning light com. Diagnostic light Instruments and warning lights control board CONTROL PANEL FOR INSTRUMENTS AND WARNING LIGHTS Specification Desc./Quantity Ground lead Plug with contacts...
  • Page 52 Runner Purejet Electrical system Specification Desc./Quantity Headlamp warning light Instrument lighting Checks and inspections Battery recharge circuit The recharge circuit has a three phase generator with permanent magneto. The generator is directly connected to the voltage regulator. The voltage regulator is connected directly to the earth and battery positive passing through the 15A protection fuse.

  • Page 53: Starter Motor

    Runner Purejet Electrical system Voltage regulator check With the battery fully charged, measure the volt- age in the battery poles with engine at high speed. The voltage must not exceed 15.2 volt. If higher voltage is found, replace the regulator. At voltage less than 13 volt, proceed with checks on the stator and relevant wiring.
  • Page 54 Runner Purejet Electrical system - Use a multimeter to check the continuity of the positive and negative power supply cable. - Make sure the connections are good. If no faults are found, replace the starter. Specific tooling 020331Y Digital multimeter Dynamic tests Check the battery voltage after it has not been used for a few hours.
  • Page 55 Runner Purejet Electrical system Carry out a no-load absorption test. Remove the transmission cover. Remove the starter pinion. With the starter motor in no-load, maximum absorption must be 10 A with power supply voltage ≥ 12V. STARTER MOTOR Specification Desc./Quantity Starter motor Voltmeter Starter motor contactor...
  • Page 56 Runner Purejet Electrical system Turn signals system check The turn indicator circuit is managed by an inter- mittent device. If there are any problems with this circuit check: - The 7,5A fuse indicated in the photograph after removing the front cowling. - Using a multimeter, that the BLACK-BLUE cable to the turn indicator connector has a voltage of +12V...
  • Page 57 Runner Purejet Electrical system The oil mix warning light performs a timed check of 3" every time the key is turned to ON. The check is managed by the turn indicator device which ap- plies a voltage of 12 v to the oil warning light bulb. If on turning the key to ON the control is not carried out check: - Bulb efficiency...
  • Page 58 Runner Purejet Electrical system COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR AP- PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
  • Page 59 Runner Purejet Electrical system If the battery needs topping up very frequently, check the vehicle electrics: the battery is probably working in overload conditions which will lead to rapid deterioration. 2) Check the charge After topping up the electrolyte, check the density using a densimeter (see figure).
  • Page 60 Runner Purejet Electrical system CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE. CAUTION IN EMERGENCIES, THE CHARGING TIME CAN BE DECREASED TO 5-6 HOURS. CAUTION ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY.
  • Page 61 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 62 Runner Purejet Engine from vehicle Removal of the engine from the vehicle - Remove the side panels - Remove the muffler Remove the rear brake line clamps on the trans- mission cover as shown in the figure - Loosen the 5 rear wheel clamping screws to re- move the brake calliper - Remove the brake calliper using the 2 screws shown in the figure.
  • Page 63 Runner Purejet Engine from vehicle - Remove the generator cable connector Remove the fuel connectors from the fuel injector, as follows: - Press the union pipe downwards - Hold the pipe downwards and pull the safety ring upwards - Extract the connector from the fuel injector If the connector is difficult to extract, do not force it too much and combine the rotation movement with pushing-pulling stresses.
  • Page 64 Runner Purejet Engine from vehicle - Remove the screw fixing the fuel piping clamp to the engine on the flywheel side - Remove the electric connectors from the fuel and air injector - Remove the electric connector from the throttle body - Remove the plastic clamp connecting the electric cable of the throttle body to the air pipe shown in...
  • Page 65 Runner Purejet Engine from vehicle - Remove the belt cooling cover - Release the mixer control cable using the special hole as shown - Remove the starter wiring from the relay and from the grounding wire - Remove the plastic clamp connecting the starter wiring to the swinging arm - Remove the screw fixing the fuel piping clamp to the engine on the transmission side...
  • Page 66 Runner Purejet Engine from vehicle - Remove the coolant temperature sensor con- nector - Remove the cooling system piping from the en- gine and discharge the fluid - Remove the air filter sucking sleeve - Remove the lower suspension fixing - Use two 17 mm Allen wrenches to remove the engine/swinging arm fixing pin - Remove the oil mixer pipe from the tank...
  • Page 67 Runner Purejet Engine from vehicle - To refit, perform the operations in the reverse di- rection and ensure that the electric wiring is prop- erly fixed to components such as: air injector, fuel injector, throttle body, generator, coolant temper- ature sensor. - Carefully clean the connectors removing any dirt and foreign material - Respect the clamps of the fuel lines to the engine.
  • Page 68 Runner Purejet Engine from vehicle ENG VE - 8...
  • Page 69 INDEX OF TOPICS NGINE...

  • Page 70: Automatic Transmission

    Runner Purejet Engine Automatic transmission Transmission cover - Loosen the 15 screws and remove the transmis- sion cover with the aid of a mallet. N.B. THE CRANKCASE IS SLIGHTLY BLOCKED BY THE TIGHT FIT BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ON THE CRANKCASE.

  • Page 71: Inspecting The Clutch Drum

    Runner Purejet Engine Removing the driven pulley - Lock the clutch bell housing with the specific tool. - Remove the nut, the clutch bell housing and the whole of the driven pulley assembly. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE PULLEY MOUNTED.
  • Page 72 Runner Purejet Engine - Using a 34 mm socket wrench remove the clutch locking nut. - Loosen the central screw thereby undoing the driven pulley unit - Separate the components. Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch Inspecting the clutch - Check the thickness of the clutch mass friction material.
  • Page 73 Runner Purejet Engine - Remove the three guide pins and the mobile half pulley. Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EX- TRACTION PLIERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 74 Runner Purejet Engine Inspecting the driven fixed half-pulley - Check that there are no signs of wear on the work surface of the belt. If there are, replace the half- pulley.. - Make sure the bearings do not show signs of un- usual wear.

  • Page 75: Refitting The Driven Pulley

    Runner Purejet Engine - Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole.
  • Page 76 Runner Purejet Engine • Measure the free length of the mobile driving half- pulley. Characteristic Standard length: 110 mm Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation - Measure the free length of the spring Characteristic Standard length 118 mm...

  • Page 77: Removing The Driving Pulley

    Runner Purejet Engine Nut locking clutch unit on pulley 55 ÷ 60 Nm Refitting the driven pulley • Refit the driven pulley assembly, the clutch bell and the nut using the specific tool. Specific tooling 020565Y Flywheel lock calliper spanner Locking torques (N*m) Locking torque: 40 ÷...
  • Page 78 Runner Purejet Engine Inspecting the rollers case 1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation. 2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary).
  • Page 79 Runner Purejet Engine Refitting the driving pulley - Manually move the mobile driven half-pulley away pulling it towards the clutch unit and insert the belt repeating the direction of rotation of the first fitting. N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THE WORDING CAN BE READ, IN THE CASE THAT THIS DOES NOT SHOW A FITTING SIDE.
  • Page 80 Runner Purejet Engine Removing the hub cover • Remove the transmission cover • Remove the clutch assembly • Discharge the rear hub oil. • Remove the 5 screws indicated in the figure. • Remove the hub cover with driven pulley shaft. See also Refitting the clutch Removing the wheel axle...
  • Page 81 Runner Purejet Engine Removing the driven pulley shaft bearing - Remove the seeger ring inside the cover. - Remove the oil seal from the outside. - Remove the centring dowels and position the cover on a plane. - Position the special tool on the internal track of the bearing and remove said bearing with the aid of a press.
  • Page 82 Runner Purejet Engine Refitting the driven pulley shaft bearing - Support the inner track of the bearing from the outside of the hub cover with the specific tool posi- tioned under the press and insert the driven pulley axle. - Refit the oil seal flush with the cover. Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft...

  • Page 83: Removing The Stator

    Runner Purejet Engine Refitting the ub cover • Refit the complete wheel axis. • Refit the intermediate gear being careful of the two shim adjustments. • Apply LOCTITE 510 for surfaces on the hub cov- er and refit it with the complete pulley shaft. •...
  • Page 84 Runner Purejet Engine • Use a specific extractor to remove the flywheel Specific tooling 020162Y Flywheel extractor • Remove the two studs of the revolutions sensor to the coolant inlet pipe. • Remove the coolant inlet duct • Remove the two stator fixing screws •...
  • Page 85 Runner Purejet Engine Refitting the flywheel cover • Fit the rubber seal on the flywheel con- nector and around the inlet coolant hose. • Keeping the flywheel connector rubber clamp on the coolant inlet hose, refit the flywheel cover paying attention in inserting the strap in the groove.

  • Page 86: Removing The Cylinder Head

    Runner Purejet Engine Removing the cylinder head • Use a TORX 20 wrench to remove the air feeding line from the injection head as shown in the figure. • Remove the injection head, including the fuel in- jector and the pressure regulator, using the 2 screws shown in the figure •...
  • Page 87 Runner Purejet Engine • Remove the coolant outlet union from the head with the relevant O-ring, using the two screws, as shown in the figure. • Remove the head inside recirculation duct as shown in the figure. • Remove the head using the 4 screws as shown in the figure.
  • Page 88 Runner Purejet Engine Removing the cylinder - piston assy. • Remove the cylinder holding the piston in order to prevent damage • Remove the 2 plug stops by a screwdriver inser- ted into the special slits on the piston • Remove piston pin and remove the piston N.B.

  • Page 89: Inspecting The Small End

    Runner Purejet Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER AL- LOWED, SHOWS SIGNS OF WEAR OR OVER- HEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT"...
  • Page 90 Runner Purejet Engine - Measure the outer diameter of the piston, per- pendicular to the pin axis. - Take the measurement in the position shown in the figure To classify the cylinder-piston fitting, check the ap- propriate table See also Cylinder - piston assy.

  • Page 91: Removing The Piston

    Runner Purejet Engine Removing the piston • Insert the roller in the connecting rod • Fit piston and wrist pin on the connecting rod, with piston facing the outlet • Insert the wrist pin stop ring in the specific tool with the aperture in the position shown on the tool, as in the figure •...
  • Page 92 Runner Purejet Engine • Fit the wrist pin stop using the plug as shown in the figure Specific tooling 020166Y Pin lock fitting tool Choosing the gasket • Temporarily fit the cylinder on the piston, without the basic gasket. • Fit a dial gauge on the specific tool, using the short union as shown in the figure.
  • Page 93 Runner Purejet Engine Refitting the head and timing system components • Carefully clean the head, removing any carbon residues • Check the perfect condition of the fitting surfaces • Check that the O-rings are not broken, otherwise replace them • Screw the 4 head fixing nuts and tighten them in crossed sequence to the prescribed torque Locking torques (N*m) Head fixing nuts: 10 ÷11 Nm...
  • Page 94 Runner Purejet Engine • Refit the dust cover onto the air injector. N.B. NOTE THAN WHEN THE AIR INJECTOR IS RE- FITTED, THE CARBON DAM O-RING MUST BE NEW. IF A NEW AIR INJECTOR IS FITTED, THE NEW CARBON DAM RING IS ALREADY PRESENT.
  • Page 95 Runner Purejet Engine - Remove the air injector - The carbon dam ring must be broken to be re- moved. - Carefully clean the air injector and the seat re- moving any carbon residues. - Check that the sealing rings exhibit no wear, or replace them.
  • Page 96 Runner Purejet Engine - Remove the throttle body with manifold, diaphragm, gasket and blade support - Remove the volumetric compressor - Remove the thermal unit - Remove the starter See also Cylinder assy. and timing system Removing the driving pulley Removal Removing the driven pulley Splitting the crankcase halves...
  • Page 97 Runner Purejet Engine - Install the specific tool with relevant guard on the transmission side crankcase half. Use four M6 screws of a suitable length. - Use a 17 mm Allen wrench to remove the crank- shaft from the transmission side crankcase half. Removing the crankshaft - Install the specific tool on the half crankcase on the transmission side using four M6 screws of an...
  • Page 98 Runner Purejet Engine - Use the specific tool to remove any bearings left on both crankcase halves. Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing Refitting the crankshaft bearings - This operation requires assembly by temperature - Dip the bearings in oil bath when this is still cold.
  • Page 99 Runner Purejet Engine 008119Y009 Tube to assemble shafts and axles Inspecting the crankshaft components - Check for any abnormal wear on the eccentric track. - To check using the dial gauge, see the section «Checking crankshaft alignment» Inspecting the crankshaft alignment With the specific tool shown check that the eccen- tricity of the surfaces of diam.
  • Page 100 Runner Purejet Engine Inspecting the crankcase halves - Remove the oil seals from both crankcase halves using a screwdriver. - Clean the fitting surfaces removing Loctite resi- dues and residues of the paper seal on the cylin- der. - For this operation, use specific products available on the market.
  • Page 101 Runner Purejet Engine Refitting the crankshaft - Place the transmission side crankcase half on two wooden supports. - Refit the water pump rotor (note that the thread- ing is anticlockwise) - Use the thermal gun to heat the bearing seat to approx.
  • Page 102 Runner Purejet Engine - Prepare the fitting surface using the recommen- ded product applying a thin layer after degreasing the surface with a suitable solvent (e.g. trichloro- ethylene) Recommended products Loctite 510 Liquid sealant Gasket - Assemble the equipment need to close the crank- case half (screws, wrench).
  • Page 103 Runner Purejet Engine Refitting the crankcase halves - Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur- face using a suitable solvent (e.g. trichloroethy- lene) - Heat the flywheel-side half crankcase with a ther- mal gun.
  • Page 104 Runner Purejet Engine Air compressor Removal Air compressor removal - Remove the throttle body manifold - Remove the air piping union from the injection head using a Torx 25mm wrench - Remove the air piping support bracket fixing screw from the transmission covers. - Remove the 4 screws fixing the air compressor to the crankcase, as shown in the figure.
  • Page 105 Runner Purejet Engine Overhaul Air compressor check - Check the presence of any unusual wear, traces of overheating on the roller contacting with the ec- centric, as shown in the figure. - Use a feeler gauge to measure the axial play of the control roller by placing the blade between roller and one of the two shim adjustments.
  • Page 106 Runner Purejet Engine - Place the shaft with the eccentric at its lower dead point. - Insert the compressor into the crankcase, cor- rectly placing the reference dowels. - Refit the sealing ring. - Refit the 4 fixing screws tightening to the prescri- bed torque.

  • Page 107: Oil Pump

    Runner Purejet Engine Crankshaft oil seals Refitting - Install a new oil seal on the flywheel side using the specific tool punch. The flywheel side oil seal can be recognised by the smaller diameter. N.B. USE OF THE TOOL IS NOT COMPATIBLE WITH THE MOUNTED KEY Specific tooling 020340Y Flywheel and transmission oil seals...
  • Page 108 Runner Purejet Engine Removal - Remove the transmission cover - Remove driving pulley - Remove the 2 screws shown in the figure - Remove the pipe gasket from the case as shown in the figure - Remove the pipe from the oil inlet union in the pump case See also Removing the driving pulley...
  • Page 109 Runner Purejet Engine Refitting - To refit, perform the removal procedures in the reverse direction. - Perform purging after refitting, using the screw shown in the figure. ENG - 41...
  • Page 110 Runner Purejet Engine ENG - 42...
  • Page 111 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 112: Removing The Front Wheel

    Runner Purejet Suspensions Front Removing the front wheel - Support the vehicle in such a way that the front wheel is raised. - Using two 18 mm hexagonal wrenches remove the front wheel axle. Front wheel hub overhaul - Remove the front wheel - Keep the wheel level by means of two wooden wedges - With the appropriate pliers and tool remove the...
  • Page 113 Runner Purejet 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 114: Front Fork

    Runner Purejet Suspensions Removal - Remove the front handlebar cover. - Remove the rear handlebar cover. - After removing the transmissions and discon- necting the electrical terminals, remove the bolt «A» and the handlebar - Check all components and replace faulty parts. N.B.
  • Page 115 Runner Purejet Suspensions Removal - Remove the front brake calliper. - Remove the odometer cable from the reduction gear box. - Remove the front mudguard. - Remove the handlebar. After removing the steering ring-nut using the spe- cial tool, lean the vehicle on one side and extract the steering tube.
  • Page 116 Runner Purejet Suspensions - Remove the dust guard (1) using a screwdriver to prise it out. - Remove the seeger (2) and remove the power pipe. N.B. GREASE THE SPRINGS AND THE BUSHINGS BEFORE REFITTING, WITH A SMALL QUANTI- TY OF GREASE (AROUND 3 GR.) Recommended products AGIP GREASE MU3 Grease for odometer transmission gear case...

  • Page 117: Steering Column

    Runner Purejet Suspensions Refitting Lubricate the seats and the balls with the grease recommended. - Lock at the prescribed torque and turn the key anticlockwise by 90° to 100°. Specific tooling 020055Y Wrench for steering tube ring nut Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous-calcium based grease to protect...
  • Page 118 Runner Purejet Suspensions - Using the special tool, refit the upper and lower bearing seats on the headstock. Specific tooling 001330Y Tool for fitting steering seats Steering bearing Removal Bearing housing on the fork overhaul Check the condition of the fifth wheel and the fifth wheel seat on the fork (steering tube).
  • Page 119 Runner Purejet Suspensions - Remove the handlebar. - Remove the cover of the steering collar shown in the figure - Remove the collar of the steering bearing using the specific tool Specific tooling 020055Y Wrench for steering tube ring nut See also Front handlebar cover Rear handlebar cover...

  • Page 120: Removing The Rear Wheel

    Runner Purejet Suspensions Removing the rear wheel - Remove the wheel loosening the five clamps. Refitting the rear wheel - On refitting, tighten to the prescribed torque in a cross over pattern. Locking torques (N*m) Rear wheel: 20 - 25 Nm Shock absorbers Removal To replace the shock absorber you just need to...
  • Page 121 Runner Purejet Suspensions Locking torques (N*m) Shock absorber/frame nut torque 20 to 25 Nm Shock absorber/engine pin torque 33 to 41 N·m Centre-stand Expulsion of kickstand bracket fastening pin - Remove the stand support bracket from the en- gine. - Drill a 5 mm hole in the bracket so that the pin «P»...
  • Page 122 Runner Purejet Suspensions SUSP - 12...
  • Page 123 INDEX OF TOPICS INJ PJ PURE JET INJECTION...
  • Page 124 Runner Purejet pure jet injection Introduction EMS injection system The injection system has an incorporated injection and ignition. Injection is direct and pneumatic, by air electro-injector and fuel electro-injector. Injection and ignition are phased on the 2T cycle by a phonic wheel on the flywheel and phase rpm sensor with reluctance variation.
  • Page 125 Runner Purejet pure jet injection • Fuel consumption reduction • Lubricant consumption reduction • Discharge emission reduction. Emissions are further limited by the catalyser. The injection system achieves these results by: • Air washing of the 2T cycle • Stratified load •...

  • Page 126: Troubleshooting

    Runner Purejet pure jet injection 8. Do not invert the polarity when fitting the battery. 9. To prevent damage, disconnect and reconnect the ECU system connectors only if required. Before reconnecting, check that the connectors are dry. 10. During electrical checks, do not force the tester tips into the connectors. Do not perform tests not specifically required by the manual.
  • Page 127 Runner Purejet pure jet injection Dirty fuel filter Fuel supply vent clogged 5. Ignition system Faulty spark plug Faulty coil Faulty screened cap 6. Suction circuit Air filter dirty 7. Others Incorrect reset of the gas valve position sensor 2 Injection system faults may be caused by loosened connectors. Make sure that all connections are efficient.
  • Page 128 Runner Purejet pure jet injection AUTO-DIAGNOSTIC Specification Desc./Quantity PRIORITY 1 Flashing injection indicator. This signal identifies abnormalities that could cause serious damage to the engine or stopping of the vehicle if the vehicle continues to be used. PRIORITY 2 Steady injection indicator. This denotes faults that impair the vehicle use since the engine can stop or remain idle.
  • Page 129 Runner Purejet pure jet injection • TPS RESET • CALIBRATION • ECU INFORMATION To access the individual functions, the tester must be connected to the vehicle diagnostic outlet and the ECU must be on. • To connect the scooter diagnostic tester, raise the seat •...
  • Page 130 Runner Purejet pure jet injection All the parameters can be displayed by selecting the 4 pages. In case of need, all the parameters can be stored in the tester by pressing the «TAB» key at the selected time. The parameters are stored as long as the power of the diagnostic tester is inserted.
  • Page 131 Runner Purejet pure jet injection Specification Desc./Quantity G11 P0217 Engine temperature high: the coolant tempera- ture signal voltage has reached too low voltages. They denote a very high temperature, higher than what can be indicated by the instrument panel. Flashing light G20 P1120 TPS OFFSET The voltage of TPS signals is not as expected.
  • Page 132 Runner Purejet pure jet injection Specification Desc./Quantity Light on G60 P0230 Fuel pump The ECU has detected an interruption or short cir- cuit on the power supply line of the pump. Light on G60 P0650 Check lamp. The ECU has detected an interruption or short cir- cuit on the injection indicator supply.
  • Page 133 Runner Purejet pure jet injection This function displays the parameters stored previously. As already specified in the description of the parameter function, parameters are stored by pressing the «TAB» key at the selected time. The diagnostic tester can contain a single memorisation. It is cancelled out automatically as soon as power is disconnected from the tester.
  • Page 134 Runner Purejet pure jet injection component layout POSITION OF COMPONENTS Specification Desc./Quantity Temperature sensor "WARNING" light HV coil N° 2 15 A fuses Diagnostic socket EMS electronic injection control unit Throttle body Coolant temperature sensor INJ PJ - 12...
  • Page 135 Runner Purejet pure jet injection Specification Desc./Quantity Fuel injector fuel pump Flywheel - rpm timing sensor terminal layout on cpu 1 - Ground 3 - Fuel injector (negative) 4 - To diagnostic indicator (negative) 5 - Coolant temperature indicator (button negative) 7 - TPS 1 signal 9 - Coolant temperature sensor (positive) 10 - TPS 2 signal...
  • Page 136 Runner Purejet pure jet injection 18- TPS sensor positive (+5V) 19 - Phase rpm sensor positive 20 - Phase rpm sensor negative 21 - Serial line for diagnostic tester EMS system diagram SYSTEM DIAGRAM Specification Desc./Quantity Voltage regulator Flywheel magneto pick - up Fuel injector Water temperature sensor Throttle body pos.
  • Page 137 Runner Purejet pure jet injection Specification Desc./Quantity Diagnostics outlet cpu power circuit INJECTION ECU POWER SUPPLY CIRCUIT Specification Desc./Quantity Injection warning light 7.5A Ignition key-switch Fuel pump Air injector Fuel injector HV coil Voltage regulator Battery 12V - 9Ah Fuse To services To flywheel magneto 1-Turn the key switch to the «ON»...
  • Page 138 Runner Purejet pure jet injection N.B. WHEN THE SWITCH IS ON «ON», ALL SERVICES ARE ACTIVATED. IF THERE ARE ANY FAULTS, REFER TO SECTION «VEHICLE ELECTRICS». 3- The ignition light is flashing. GO TO point 5 4- The ignition light does not switch on and the pump is correctly activated. Perform all the checks required in the injection light section.
  • Page 139 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 15- Check the charger. GO TO point 17 16- The ECU supplies are conform. 17- Check all electrical installation connections for any possible problems that are related to loosening or oxidation.
  • Page 140 Runner Purejet pure jet injection 1 - 15 = battery voltage YES point 25 NO point 26 25- The supply is conform. 26- Check the efficiency of the 15A fuse and of the connections to the fuse-holder (red - blue) YES point 27 NO point 28 27- Restore the continuity of the line connecting fuse with pin 15 (blue cable)
  • Page 141 Runner Purejet pure jet injection - fuel injector - H.V. coil - Voltage adjuster GO TO point 24 34- After confirmation of the correct main supply (point B) check the power supply to panel. Check the following conditions: 1 - 17 = battery voltage (switch on «ON») 1 - 17 = 0V (switch on «OFF») YES point 35 NO point 36 35- The ECU power supply to panel is conform.
  • Page 142 Runner Purejet pure jet injection 1 - 17 = battery voltage (switch on «ON») 1 - 17 = 0 Volt (switch on «OFF») YES point 45 NO point 44 44- IlThe fuse is again burnt. Check the wiring more accurately and, if necessary, replace the ECU GO TO point 34 45- Make a good visual check of the wiring to avoid possible causes for short circuits.
  • Page 143 Runner Purejet pure jet injection 1. Check that the insertion of the connection to the vehicle is correct. YES point 3 NO point 2 2. Restore the connection. 3. Turn to «OFF», wait a few seconds and turn again to «ON». If the fault persists, make the fol- lowing checks: GO TO point 4 4.
  • Page 144 Runner Purejet pure jet injection 10. Restore the wiring connection. 11. The diagnostic tester connection meets specs. If the problem persists, check the diagnostic tester and the ECU, if necessary. Injection lamp circuit THERMIC: 1 - 4 CONDITIONS: Key selector set to «ON», engine off STANDARD:Less than 0.1 V THERMIC: 1 - 4 CONDITIONS: Key selector set to "ON", engine on, no fault detected...
  • Page 145 Runner Purejet pure jet injection 3 Fuses 7.5A 4 Key switch 5 Fuel pump 6 Fuses 15A 7 Battery 12V 9Ah A Ai services B + Fixed The injection indicator should turn on every time you switch to "ON" while the engine is started. When the self-diagnosis detects a fault, it commands the lightingof the indicator according to the priority level: •...
  • Page 146 Runner Purejet pure jet injection 020481Y Control unit interface wiring 5. Remove the 7.5A fuse (white lead) and check the presence of voltage 1 - 4 = 0V YES point 6 NO point 7 6. The lamp control circuit is efficient. 7.
  • Page 147 Runner Purejet pure jet injection 13. Battery voltage is missing and the lamp is on. Access the instrument unit and disconnect the 8- pin connector. Check the ground insulation of the connection line . 1 - 4 > 1MOhm In case of faults, restore the wiring. See also autodiagnosis throttle position sensor circuit (T.P.S.)
  • Page 148 Runner Purejet pure jet injection COMPONENTS LAYOUT 1 ECU 2 TPS (Throttle Position Sensor) 3 Coolant temperature sensor A + 12V under panel B + 12V fixed The gas valve position sensor (TPS) is an integral part of the throttle body, and therefore it cannot be removed.
  • Page 149 Runner Purejet pure jet injection For the check, proceed as follows. Connect the diagnostic tester to the vehicle. Select the «parameters» function. The following values are reported: THROTTLE OPEN. % The displayed value refers to the valve opening percentage. Check that a progressive actuation of the valve corresponds to an equal increase of the opening percentage value.
  • Page 150 Runner Purejet pure jet injection P1125 TPS1 signal missing. Acknowledge- Free TPS1 ment occurs when the signal voltage is close to: 0V = short circuit 5V = open circuit P1128 TPS2 signal missing. Acknowledge- Free TPS2 ment occurs when the signal voltage is close to: 0V = short circuit 5V = open circuit...
  • Page 151 Runner Purejet pure jet injection N° 1 (TPS) - 16 (ECU) = Ohm Continuity N° 2 (TPS) - 7 (ECU) = Ohm Continuity N° 3 (TPS) - 10 (ECU) = Ohm Continuity N° 4 (TPS) - 18 (ECU) = Ohm Continuity YES point 4 NO point 3 3.
  • Page 152 Runner Purejet pure jet injection 11. Carefully check the ECU power supply. Re- place the ECU if required. GO TO point 10 12. Connect the TPS sensor connector and meas- ure the voltage. 16(-) - 18 (+) = 5 V YES point 14 NO point 13 13.
  • Page 153 Runner Purejet pure jet injection See also menù diagnosis tester T.P.S. signal reset The throttle body is supplied with gas valve and is precalibrated. Precalibration entails regulating the minimum opening of the gas valve to obtain a certain flow of air under preset reference conditions. Pre-calibration results in an optimum air capacity for the engine management during start up or during idle running, and at any possible temperature during the use of the vehicle.
  • Page 154 Runner Purejet pure jet injection 1- Connect the scooter diagnostic tester Select the «parameters» function and visualise the indicator showing the «TPS to reset» GO TO point 2 GO TO point 4 2. The diagnostic tester responds YES. Continue to make the following checks: - The throttle body is not tampered with - The control transmission is correctly registered - The connector of the throttle body is correctly connected...
  • Page 155 Runner Purejet pure jet injection Select «RESET TPS» from the menu. By using this procedure, the following indications are visualised. GO TO point 2 2. Check for possible errors Wait GO TO point 3 GO TO point 4 3. Errors present Cancel all errors Press a key GO TO point 5...
  • Page 156 Runner Purejet pure jet injection GO TO point 15 15. TPS resetting successful Press a key GO TO point 16 16. The manual procedure is completed. For a further confirmation, check that the indications reported in the parameters function comply with the instructions given for automatic reset. rpm-timing sensor circuit TERMINALS: 19 - 20 CONDITIONS: Engine driven by the starter (500-600 RPM)
  • Page 157 Runner Purejet pure jet injection • Fuel injector • Air injector • H.V. coil Every actuator is controlled with a specific timing. Control is made possible by the phase - rpm signal, coming from a phonic wheel obtained on the outer diameter of the flywheel magneto rotor. The flywheel is divided into 24 sectors and is provided with 23 teeth controlling the gap variations to the pick - up core.
  • Page 158 Runner Purejet pure jet injection Specific tooling 020481Y Control unit interface wiring 5. Check the continuity of the connection lines of the sensor from the ECU to the flywheel connector 19 - red lead= Ohm continuity 20 - brown lead= Ohm continuity YES point 7 NO point 6 6.
  • Page 159 Runner Purejet pure jet injection 8. Restore the insulation or replace the wiring. GO TO point 7 9. Check the reciprocal insulation of the lines 19 - 20 > 1MOhm YES point 11 NO point 10 10. Restore the insulation or replace the wiring. GO TO point 9 11.
  • Page 160 Runner Purejet pure jet injection 14. Restore or replace the stator with phase - rpm sensor. GO TO point 17 15. Check the phase - rpm sensor resistance 19 - 20 = Ohm…… at 20° (detected 106.7W) YES point 17 NO point 16 N.B.
  • Page 161 Runner Purejet pure jet injection H.T. coil circuit TERMINALS: 1 - 12 CONDITIONS: Engine stopped, switch in any position STANDARD VALUES: Battery voltage COMPONENTS LAYOUT 1 ECU 2 15A fuses 3 Air injector 4 Fuel injector 5 H.V. coil 6 Key switch 7 12V 9Ah Battery A + under panel B Al magnet flywheel...
  • Page 162 Runner Purejet pure jet injection The core dwelling time is optimised in function of the power required to the HV coil. Of course, longer dwelling times are used during start up. The ECU self-diagnosis also checks the coil power supply circuit, detecting interruptions or short cir- cuits.
  • Page 163 Runner Purejet pure jet injection 4. Error on the H. V. coil in «occurred» or stored status. Continue with circuit checks. Possible problems: - Uncertain contacts - Lacking insulation CHECKING THE ELECTRIC CIRCUIT 1. Connect the interface wiring. Do not connect the ECU. Disconnect the connector of the H.V. coil primary.
  • Page 164 Runner Purejet pure jet injection 7. Restore the wiring GO TO point 6 8. Check the insulation - from negative - of the control line of the coil. 1 - 12 > 1MOhm NO point 9 GO TO point 10 9.
  • Page 165 Runner Purejet pure jet injection 15. Replace the screened cap. GO TO point 14 16. Reconnect the following components: - Shielded cap - H.V. coil supply connector - ECU interface wiring: GO TO point 17 17. With the engine idle, measure the induced voltage produced by the H.V.
  • Page 166 Runner Purejet pure jet injection ignition timing check The ignition advance is electronically determined on the basis of the ECU parameters. For this rea- son, it is not possible to state reference values based on the engine rpm. The ignition advance value can be detected by the parameters function of the diagnostic tester.
  • Page 167 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light for timing control 020621Y HV cable extraction adaptor compressed air system Direct injection in the cylinder takes place by pressure of the compressed air. The injection pressure is vital to ensuring the correct fuel preparation and pulverisation of the mix.
  • Page 168 Runner Purejet pure jet injection 4- The engine rpm and pressures are lower than specifications. Check the battery and starter sys- tem. GO TO point 3 5- Engine rpm and pressure are as expected. Check that the pressure remains stable over time. YES point 16 NO point 8 6- Engine rpm are as expected and pressure is lower than specifications.
  • Page 169 Runner Purejet pure jet injection 13- Bring the system to pressure again and as soon as the starter stops rotating, close the com- pressor connection pipe at the shunting with the manometer by a flat and long pincer. Check the pressure progress.
  • Page 170 Runner Purejet pure jet injection COMPONENTS LAYOUT: 1 ECU 2 Fuses 15A 3 Air injector 4 Fuel injector 5 H.V. coil 6 Voltage regulator 7 12V - 9Ah battery A + under panel B To the magnet flywheel The air injector is the main component of the electro-pneumatic injection. For convenience, the injector called air injector even though it actually injects an air and fuel mixture.
  • Page 171 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 2- Enable the air injector diagnostic. Check the 5 sounds that denote the air injector activation. Check the tester response. YES point 3 NO point 4 NO point 5 3- The air injector has enabled 5 times and the tester has returned "test finished successfully".
  • Page 172 Runner Purejet pure jet injection 12- Check the efficiency of fuse 20A and restore the wiring if required. GO TO point 11 13- Check the continuity of the air injector control line. 13 - pink (injector connector) = continuity YES point 15 NO point 14 N.B.
  • Page 173 Runner Purejet pure jet injection 20- If very different resistive values are detected, replace the air injector. GO TO point 19 21- Check the air injector winding negative insu- lation. 1 - any pin of the injector> or = 1MOhm YES point 23 NO point 22 22- Replace the air injector.
  • Page 174 Runner Purejet pure jet injection fuel pump circuit TERMINALS: 1 - 14 CONDITIONS: Switch in «ON» position after the engine timing STANDARD VALUES: less than 0.1 V TERMINALS: 1 - 14 CONDITIONS: Switch in «ON» position after timing with engine still STANDARD VALUES: Battery voltage COMPONENTS LAYOUT: 1 ECU...
  • Page 175 Runner Purejet pure jet injection The fuel pump is a piston type supplied with a constant current motor. It was designed to supply high pressures with small capacities and low absorption, and is therefore suitable for use on reduced capacity motors.
  • Page 176 Runner Purejet pure jet injection Specific tooling 020460Y Scooter diagnosis and tester 12- No error present. The pump's electric command circuit is efficient. For a more complete check, proceed with the check on the fuel supply circuit. 13- Fuel pump error in occurred or stored status. Proceed with the check on the pump and the control circuit, paying particular attention to false contacts or uncertain insulation.
  • Page 177 Runner Purejet pure jet injection 19 - Restore the wiring. GO TO point 18 20 - Check the fuel pump control line positive in- sulation. 1 - 14 = 0V YES point 22 NO point 21 21- Restore the wiring. GO TO point 20 22 - Check the fuel pump control line negative in- sulation.
  • Page 178 Runner Purejet pure jet injection 25- A resistance of around 0 Ohm indicates the presence of a short circuit. A resistance signifi- cantly greater than the standard values indicates low conductivity. In these cases, replace the pump. GO TO point 24 26- Keeping the ECU conditions disconnected and pump connector connected, check that with the key switch in the «ON»...
  • Page 179 Runner Purejet pure jet injection COMPONENTS LAYOUT: 1 ECU 2 15A fuses 3 Air injector 4 Fuel injector 5 Bobina A.T. 6 Key switch 7 12V - 9Ah battery A+ under panel B To the magnet flywheel The petrol injector receives the pressurized fuel through the supply system. The ECU commands the injector, controlling both the time and the opening moment.
  • Page 180 Runner Purejet pure jet injection GO TO point 2 1- Connect the scooter diagnostic tester. Select function "active diagnosis". Specific tooling 020460Y Scooter diagnosis and tester 2- Activate the fuel injector diagnostic. Listen for 5 fuel injector activations. Check the diagnostic tester response.
  • Page 181 Runner Purejet pure jet injection Specific tooling 020481Y Control unit interface wiring 3. Check the efficiency of fuse 15A and restore the wiring if necessary. GO TO point 2 4. Check the continuity of the fuel injector control line 3 - white = continuity NO point 5 YES point 6 N.B.
  • Page 182 Runner Purejet pure jet injection 11. If different resistive values are detected, re- place the fuel injector mounting 12. Check the fuel injector winding negative insu- lation. 1 - any pin of the injector > or = 10 Ohm NO point 13 YES point 14 13.
  • Page 183 Runner Purejet pure jet injection coolant temperature sensor circuit Warning: We inform you that some engine malfunctions have recently been dealt with erroneously by re- placing the fuel pump without first checking the correct fitting of the clamps (shown in the picture). Therefore, before replacing the pump follow the procedure given below: 1.
  • Page 184 Runner Purejet pure jet injection The first section of the fuel supply system on the fuel injection version of the Runner consists of an outlet fitting located in the lower half of the tank. Fuel flows through the transparent-type paper filter and to the shunt, just before the pump.
  • Page 185 Runner Purejet pure jet injection TOOL INSTALLATION RESULTS IN CANCELLATION OF THE INTAKE AIR PRESSURE. DURING THE SUBSEQUENT INSPECTIONS, RUN THE STARTER ONLY WHEN EXPLICITLY STATED IN THE PROCEDURE. Specific tooling 020617Y Air pressure check kit 3. Attach the fuel pressure control kit onto the supply line. The installation may be carried out either at the pump outlet or at the injector mounting inlet.
  • Page 186 Runner Purejet pure jet injection GO TO point 8 8. Using a flat-ended caliper slowly shut the spe- cial tool hose on the injector mounting side. Check that the distributed pressure and absorbed current are within specs. NO point 10 YES point 11 Specific tooling 020616Y Fuel pressure control kit 9.
  • Page 187 Runner Purejet pure jet injection 14. Detach the fuel return duct and prepare an ad- equate container for the collection of fuel. Keeping the ammeter attached to pins 1 - 14 on the interface wiring, run the pump for one minute while turning the key-switch to «ON»...
  • Page 188 Runner Purejet pure jet injection 19. The system is capable of providing the correct fuel supply pressure. N.B. THE PRESSURE FIGURES SHOWN REFER TO A WARM ENGINE. WITH THE ENGINE COLD AND AT IDLE THE PRESSURE FIGURES MAY BE LOWER BY 0.5 BAR, DUE TO LONGER INJECTION CYCLES.
  • Page 189 Runner Purejet pure jet injection GO TO point 26 N.B. A NOTICEABLE PRESSURE LOSS WHICH OCCURS ONLY AFTER A FEW HOURS IS NORMAL. 26. When the fuel supply system is working effec- tively, it is possible to carry out the hydraulic check of the fuel injector.
  • Page 190 Runner Purejet pure jet injection Let the fuel injector open for 15 seconds by jumping pins 3 -1. Measure the fuel output from the injector: standard distribution - 14 cm3 (pressure 2.5 BAR) in 15 seconds NO point 29 YES point 30 29.
  • Page 191 Runner Purejet pure jet injection B + Fixed INJ PJ - 69...
  • Page 192 Runner Purejet pure jet injection INJ PJ - 70...
  • Page 193 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 194 Runner Purejet Braking system Rear brake calliper Removal - Disconnect the hydraulic union collecting the oil in an appropriate container. - Loosen the two support calliper clamps. Refitting - On refitting, work in the reverse order and respect the indicated torques. Locking torques (N*m) Rear brake calliper: 20 - 25 Nm Front brake calliper...
  • Page 195 Runner Purejet Braking system Removal - Disconnect the oil line from the calliper, collecting the oil in a container. - Remove the clamps highlighted in the diagram. - On refitting tighten the bolts to the prescribed tor- que. - Perform bleeding procedure on the system. Overhaul - Remove the calliper assembling bolts and take out the internal bodies and components.
  • Page 196 Runner Purejet Braking system CAUTION RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS. AFTER WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH. Locking torques (N*m) Screw tightening calliper to the support 20 ÷ 25 Calliper union: 20 ÷...

  • Page 197: Front Brake Disc

    Runner Purejet Braking system Disc screws torque 6 ÷ 6,5 N•m Wheel axle nut torque 100 ÷ 125 N•m Front brake disc Removal - Remove the front wheel loosening the axle clamp. - Unscrew five disk clamps. Refitting - On refitting, position the disc correctly, making sure to turn it in the right direction and apply medium threadblock.
  • Page 198 Runner Purejet Braking system Removal - To facilitate this operation remove the two calliper fixings. With the calliper detached from its support but still connected to the brake fluid line, remove the plastic cover by prising it with a screwdriver. - Remove the outside circlip from the brake pad pin, the leaf spring and the pads.
  • Page 199 Runner Purejet Braking system - DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL. N.B. DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SUR- ROUNDING AIR.
  • Page 200 Runner Purejet Braking system - On refitting, perform the operation in reverse. - Tighten the hydraulic lines to the prescribed tor- que and bleed the circuit. Locking torques (N*m) Hydraulic line torque 13 ÷ 18 N•m 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.
  • Page 201 Runner Purejet Braking system Refitting Before fitting, the parts must be perfectly clean and free of traces of oil, diesel fuel, grease, etc.. They should be washed thoroughly in denatured alcohol before proceeding. - Reinstall the individual parts in the reverse order to the removal, paying attention to the correct po- sitioning of the rubber parts in order to ensure leak tightness.
  • Page 202 Runner Purejet Braking system BRAK SYS - 10...
  • Page 203 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 204 Runner Purejet Cooling system Water pump - overhaul - Remove the rpm sensor /coolant delivery hose clamp - Remove the transmission cover - Remove the mixer - Position the tool as shown in the picture N.B. WHEN SECURING THE TOOL, PAY ATTEN- TION NOT TO OVERLOAD THE PLASTIC IM- PELLER.
  • Page 205 Runner Purejet Cooling system - Using the special tool, loosen the impeller shaft turning the spanner clockwise (left-handed thread) - As the thread is fully disengaged, extract the shaft using pliers. Specific tooling 020169Y Water pump crankshaft fitting and re- moval spanner - Using the special hook, remove the sealing ring from its housing as shown in the picture.
  • Page 206 Runner Purejet Cooling system - Lubricate the oil seal and push it home using the special tool as shown in the picture Specific tooling 020168Y Water seal punch mount on half- crankcase Using the air heater, warm up the water pump bearing housing, without directing the air flow di- rectly against the oil seal - Lubricate the end of the water pump shaft on the...
  • Page 207 Runner Purejet Cooling system Removal • Detach the coolant hose from the head, partially draining the system. • Remove the cylinder head. • Remove the two fixing screws and hence the thermostat. Check 1) Visually check that the thermostat is not dam- aged.
  • Page 208 Runner Purejet Cooling system Refitting • Refit the thermostat onto the head, fol- lowing the removal operations in the reverse order, and paying attention in inserting the groove on the thermostat on the reference on the head. COOL SYS - 6...
  • Page 209 INDEX OF TOPICS CHAS HASSIS...

  • Page 210: Rear Rack

    Runner Purejet Chassis Seat - Remove the two screws shown in the picture. Rear rack - Remove the side fairings - Remove the three screws shown in the picture See also Side fairings Rear handlebar cover - Remove the three screws, disconnect the elec- trical connections and the odometer transmission.
  • Page 211 Runner Purejet Chassis part upwards to prevent damaging the plastic joints, . Headlight assy. - Remove the front grill - Remove the three screws shown in the picture and disconnect the electrical connections. See also Legshield Frame central cover - Remove the front shield - Loosen the three screws shown in the picture.
  • Page 212 Runner Purejet Chassis Headlight assy. - Remove the screw shown in the figure and re- move the grill, pulling it upward and then out. Removing the ignition key-switch when on *off* - Remove central cover . - Insert a small centre-punch through the hole shown by the arrow in the figure and push until the retaining tooth on the master cylinder is released: whilst keep the punch pressed against the tooth,...
  • Page 213 Runner Purejet Chassis Legshield Footrest - Remove the side - Remove the two screws and loosen the joints very carefully See also Side fairings Side fairings Air grid - Remove the screws and detach the air conveyor grille from the side. Air conveyor - Remove the air grille - Loosen the screws shown in the picture.
  • Page 214 Runner Purejet Chassis • Remove the rear grille • Remove the air conveyor • To remove the side panel, remove the two rear screws, the screw on the rim of the seat, the screw located near the conveyor, the two screws located on the footrest, the screw located under the footrest and the screw to connect with the front panel.

  • Page 215: Fuel Tank

    Runner Purejet Chassis spoiler Rear spoiler Remove the 2 built-in hexagonal head screws. Fuel tank - Remove central cover - Loosen the three screws highlighted in the pic- ture, disconnect the piping and the electrical con- nections being careful not to let gasoline spill out. See also Frame central cover Rear central cover...

  • Page 216: Front Mudguard

    Runner Purejet Chassis Front mudguard Loosen the four screws fixing the fender to the fork. Radiator fan - Remove Central cover - Remove the three radiator fastening screws and the radiator tube clips. The radiator contains liquid so wait for the engine to be cooled down com- pletely to avo-id serious burns before removing it.
  • Page 217 Runner Purejet Chassis Expansion tank - Remove the front shield - Unscrew the two screws shown in the picture and remove the piping. CAUTION DO NOT ALLOW THE COOLANT TO DRIP. Mixture oil tank - Remove helmet carrier compartment - Remove the two screws shown in the picture - Disconnect the cabling from the oil mix level transmitter - Disconnect the oil pump from the tank.

  • Page 218: Lower Cover

    Runner Purejet Chassis Front central cover - Remove the two screws indicated in the picture. Lower cover - To remove this element it is necessary to remove the Fork removal - Loosen the three screws shown in the picture and also remove the screw which fixes the air duct for the cooling transmission.
  • Page 219 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 220 Runner Purejet Pre-delivery Aesthetic inspection Appearance checks: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Fastenings check - All tightening torques - External fairing screws Electrical system Electrical system - Fill the battery with battery acid, charge it with a suitable charger. - Key switch - Low beam lights, high beam lights, warning lights, parking lights - Headlight adjustment...
  • Page 221 Runner Purejet Pre-delivery IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION.
  • Page 222 Runner Purejet Pre-delivery − Throttle excursion and adjustment. − Homogeneous steering turning. PRE DE - 4...
  • Page 223 INDEX OF TOPICS TIME...
  • Page 224 Runner Purejet Time Engine ENGINE Code Action Duration 001001 Eng. from frame - Removal and refit 003057 Engine retainer - Tighten nuts Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase- Replace- ment TIME - 2...
  • Page 225 Runner Purejet Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001118 Bench bearings - Replace- ment 001099 Oil seal flywheel side- Re- placement 001100 Oil seal clutch side - Replace- ment TIME - 3...
  • Page 226 Runner Purejet Time Cylinder assy. PISTON - CYLINDER - TEST PROBE ASSEMBLY Code Action Duration 001002 Cylinder-Piston - Replace- ment 001107 Cylinder/piston - Service / clean TIME - 4...
  • Page 227 Runner Purejet Time Cylinder head assy. INLET MANIFOLD - HEAD Code Action Duration 001056 Head gasket - Replacement 001013 Inlet manifold- Replacement 003056 Head/cylinder - Nuts tighten- TIME - 5...
  • Page 228 Runner Purejet Time INJECTOR SUPPORT Code Action Duration 001126 Head - Replacement 001093 Spark plug - Replacement 001057 Thermostat - Replacement 007010 Bleed valve - Replacement 005110 Fuel injector mounting - Re- placement 005111 Air injector - Replacement 005112 Air injector - Service 001061 O-Ring tube coolant delivery- Replacement...
  • Page 229 Runner Purejet Time Driven pulley DRIVEN PULLEY Code Action Duration 001110 Driven pulley- Replacement 001012 Driven pulley - Service 001022 Clutch - Replacement 003072 Clutch assembly - Check wear 001155 Clutch bell - Replacement TIME - 7...
  • Page 230 Runner Purejet Time Oil pump OIL PUMP Code Action Duration 001019 Mixer belt - Replacement 001028 Mix gear movement- Re- placement 001018 Mixer - Replacement TIME - 8...
  • Page 231 Runner Purejet Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - replace 001066 Driving pulley- Removal and refit 001066 Driving pulley - Service 001011 Driving belt - Replacement TIME - 9...
  • Page 232 Runner Purejet Time Transmission cover TRANSMISSION COVER - FEMALE SCREW Code Action Duration 001096 Transmission crankcase cov- er - Replacement 001135 Transmission cover bearing - Replacement 001131 Transmission air intake - Re- placement TIME - 10...
  • Page 233 Runner Purejet Time Water pump WATER PUMP Code Action Duration 001113 Water pump - Replacement 001062 Pump command shaft - Re- moval and refit TIME - 11...
  • Page 234 Runner Purejet Time Starter motor STARTER Code Action Duration 001017 Starter pinion - Replacement 001020 Starter motor - change 005045 Starter cable assembly - Re- placement TIME - 12...
  • Page 235 Runner Purejet Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - Replace- ment 001058 Flywheel - Replacement 001067 Stator - Removal and refit TIME - 13...
  • Page 236 Runner Purejet Time Belt cooling duct BELT REFRIGERATION TUBE Code Action Duration 001132 Transmission air intake pipe - Replacement 001131 Transmission air intake - Re- placement TIME - 14...
  • Page 237 Runner Purejet Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body TIME - 15...
  • Page 238 Runner Purejet Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 16...

  • Page 239: Air Cleaner

    Runner Purejet Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement 001015 Air filter box - Replacement 001027 Bodywork / cleaner union- Replacement 004122 Cleaner / Throttle body union - Replacement TIME - 17...
  • Page 240 Runner Purejet Time Frame KICKSTAND FRAME Code Action Duration 004001 Frame- Replacement 006001 Frame - Painting 004004 Kickstand - Replacement 001053 Stand bolt - Replacement TIME - 18...
  • Page 241 Runner Purejet Time Side fairings SIDE FAIRING Code Action Duration 004085 Fairing (1) - Replacement 004012 Rear fairings - Removal and refitting 004059 Spark plug inspection flap - Replacement 006008 Rear side panel - Replace- ment TIME - 19...
  • Page 242 Runner Purejet Time Rear cover LOWER SHIELD FAIRING Code Action Duration 004022 Shield lower section - Re- placement TIME - 20...
  • Page 243 Runner Purejet Time Central cover CENTRAL FAIRING Code Action Duration 004011 Central chassis cover - Re- placement 004068 Passenger handgrip - Re- placement 004056 Upper rear light cover - Re- placement 006040 Passenger handle - Paint- work TIME - 21...
  • Page 244 Runner Purejet Time CENTRAL FAIRING Code Action Duration 004132 Semishield - Paintwork 004133 Semishields- Replacement 006039 Semishield - Replacement TIME - 22...
  • Page 245 Runner Purejet Time Mudguard REAR AND FRONT MUDGUARD Code Action Duration 004009 Rear mudguard - Replace- ment 004002 Front mudguard - Replace- ment 006003 Mudguard - Painting TIME - 23...
  • Page 246 Runner Purejet Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - Replacement 004109 Fuel tank breather - Replace- ment 004110 Fuel tank hose - Replace- ment 005010 Tank float - Replacement TIME - 24...
  • Page 247 Runner Purejet Time Tank oil OIL TANK MIXER - DEGASSER Code Action Duration 004017 Oil reservoir - Replacement 004095 Oil reservoir cock - Replace- ment 005018 Oil reservoir float - Replace- ment 004091 Oil reservoir hose - Replace- ment TIME - 25...
  • Page 248 Runner Purejet Time Expansion tank EXPANSION TANK Code Action Duration 007001 Expansion tank - Replace- ment TIME - 26...
  • Page 249 Runner Purejet Time Radiator RADIATOR Code Action Duration 007002 Water cooler - Replacement 007003 Coolant delivery and return pipe - Replacement 001052 Coolant - Replacement TIME - 27...
  • Page 250 Runner Purejet Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Re- moval and refit TIME - 28...
  • Page 251 Runner Purejet Time Steering column bearings STEERING THRUST WASHER Code Action Duration 004119 Bearing / upper steering fifth wheel - Replacement 003002 Steering thrust washer - Re- placement 003073 Steering clearance - Adjust- ment TIME - 29...

  • Page 252: Handlebar Covers

    Runner Purejet Time Handlebar covers ODOMETER - HANDLEBAR COVER Code Action Duration 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement 004018 Handlebar front section - Re- placement 004019 Handlebar rear section - Re- placement 006013 Front part of handlebar - Paintwork TIME - 30...
  • Page 253 Runner Purejet Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002080 Rear brake oil bleeding sys- tem - Replacement 002067 Rear brake pump - Replace- ment 002020 Rear brake pipes - Removal and refitting 002037 Brake or clutch lever - Re- placement 002071 Left hand grip - Replacement...
  • Page 254 Runner Purejet Time HANDLEBAR COMPONENTS Code Action Duration 004066 Rear-view mirror - Replace- ment 003061 Accelerator transmission - adjust 003001 Handlebar - Removal and re- 002060 Throttle grip - Replacement 002059 Right hand grip - Replace- ment 002024 Front brake pump - Removal and Refitting 002018 Front brake pump - Service...
  • Page 255 Runner Purejet Time Seat SEAT Code Action Duration 004003 Saddle - Replacement Turn signal lights OPTICAL UNIT Code Action Duration 005008 Front headlamp bulbs - Re- placement 005002 Front light - Replacement TIME - 33...
  • Page 256 Runner Purejet Time Code Action Duration 005044 Front lights cable unit- Re- placement FRONT TURN INDICATORS Code Action Duration 005012 Front direction indicators - Replacement 005067 Front turn indicator bulb - Re- placement TIME - 34...

  • Page 257: Front Wheel

    Runner Purejet Time BACK HEADLIGHT Code Action Duration 005066 Rear light bulbs - Replace- ment 005005 Tail light - Replacement 005028 Rear light assembly glass - Replacement 005022 Rear turn indicators-Replace- ment 005068 Rear turn indicator bulb- Re- placement 005048 Licence plate holder - Re- placement Front wheel...

  • Page 258: Rear Wheel

    Runner Purejet Time Code Action Duration 004123 Front wheel - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Removal and refit 003040 Front wheel bearings - Re- placement Grease tone wheel or drive Please take note that the code has been intro- duced: 900001 - Tone wheel / drive greasing - 15'.
  • Page 259 Runner Purejet Time REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replace- ment 001071 Rear wheel rim - Removal and refit 003063 Tyre pressure - Check 006018 Wheel rim - Paintwork 002070 Rear brake disc - Replace- ment 002028 Rear wheel hub - Replace-...

  • Page 260: Fuel Pump

    Runner Purejet Time Fuel pump SUPPLY SYSTEM Code Action Duration 004072 Fuel filter - Replacement 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replace- ment 004138 Fuel reverse pipe - Replace- ment TIME - 38...
  • Page 261 Runner Purejet Time Electric devices FRONT ELECTRIC DEVICES Code Action Duration 005113 Plug with contacts - Replace- ment 005069 Left switch - Replacement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement 005039 Headlight switch - replace TIME - 39...
  • Page 262 Runner Purejet Time ELECTRIC DEVICES LOCKS Code Action Duration 004096 Lock series - Replacement 005016 Key switch - Replacement 004010 Anti-theft lock - Replacement ELECTRIC DEVICES Code Action Duration 001069 HV coil - replace 001094 Spark plug cap - Replace- ment 001023 Control unit - Replacement...
  • Page 263 Runner Purejet Time BATTERY ELECTRIC DEVICES Code Action Duration 005052 Fuse - Replacement 005011 Start-up remote control switch - Replacement 005025 Fuse holder - Replacement TIME - 41...
  • Page 264 Runner Purejet Time BATTERY Code Action Duration 005007 Battery - Replacement 005046 Battery cover - change Transmissions TIME - 42...

  • Page 265: Brake Callipers

    Runner Purejet Time TRANSMISSIONS Code Action Duration 002051 Complete odometer trans- mission - Replacement 002063 Complete gas command trans. - Replacement 002054 Complete gas command or splitter trans. - Replacement 002057 Splitter transmission - com- plete throttle body - Replace- ment 002058 Splitter transm.
  • Page 266 Runner Purejet Time Code Action Duration 003070 Front brake pads / Shoes - Check wear REAR BRAKE CALLIPER Code Action Duration 003071 Rear brake pads - Wear check 002002 Rear brake pads - replace 002068 Rear brake calliper - Check 002048 Rear brake calliper - Re- placement...
  • Page 267 Runner Purejet Time Fuel tank filler flap GASOLINE DOOR - STEER BLOCK Code Action Duration 004135 Fuel tank port - Replacement 002082 Fuel tank cap opening drive - Replacement TIME - 45...
  • Page 268 Runner Purejet Time Helmet bay HELMET HOLDER Code Action Duration 004016 Helmet-compartment - Re- moval and refit 004054 Seat lock hook - Replace- ment Rear wheel axle TIME - 46...

  • Page 269: Front Suspension

    Runner Purejet Time REAR WHEEL AXLE Code Action Duration 001010 Reduction gear-Service 003065 Gear box oil - Replacement 004145 Rear wheel axle - Replace- ment Front suspension FRONT FORK Code Action Duration 003051 Complete fork - Replacement 003041 Fork stanchion - Replace- ment 003048 Oil seal fork - Replacement...
  • Page 270 Runner Purejet Time Code Action Duration 003010 Front suspension - Service Cooling system COOLING SYSTEM Code Action Duration 007009 Head-pump by-pass rubber coupling - Replacement TIME - 48...

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