Gilera Runner RSTPurejet Service Manual
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Gilera Runner RSTPurejet Service Manual

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MANUALE STAZIONE DI SERVIZIO
633600 - 633607
Runner RST Purejet

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Summary of Contents for Gilera Runner RSTPurejet

  • Page 1 MANUALE STAZIONE DI SERVIZIO 633600 - 633607 Runner RST 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 Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
  • 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 RST 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 RST Purejet Characteristics Dimensions and mass SIZE AND WEIGHT Specification Desc./Quantity Ready for road weight 112 ± 5 Kg Width 750 mm Length 1840 mm Height 1210 mm Wheelbase 1270 mm Engine ENGINE Specification Desc./Quantity Type single-cylinder, two-stroke Number of cylinders Bore Stroke 39.3 mm...

  • Page 10: Electrical System

    Runner RST Purejet Characteristics Capacities CAPACITY Specification Desc./Quantity Gas tank in plastic, 7 l capacity (approximate value) includ- ing a reserve of ~ 1.5 l Oil tank mixer ~ 1.6 l (including a reserve of 0.4 l) Cooling circuit ~ 0.90 l Rear hub oil Quantity: approx.

  • Page 11: Wheels And Tyres

    Runner RST Purejet Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Front tyre Without inner tube: 120/70-14" 55P Rear tyre Tubeless 140/60 x 13'' Tyre pressure Front wheel: 1.6 bar / Rear wheel: 1.8 bar Rims Front: 3.00 x 14" Rear : 3.50 x 13"...
  • Page 12 Runner RST Purejet Characteristics Name Torque in Nm Frame - swing arm bolt * 33 ÷ 41 Shock-absorber - frame nut * 20 ÷ 25 Shock-absorber - engine bolt * 33 ÷ 41 Wheel axle pin* 100 ÷ 125 Stand pin 18.5 ÷...

  • Page 13: Assembly Clearances

    Runner RST Purejet Characteristics Name Torque in Nm Driven pulley nut 40÷ 44* 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 ÷...
  • Page 14 Runner RST Purejet Characteristics Piston rings SEALING RINGS Name Description Dimensions Initials Quantity Sealing ring 0.10 ÷ 0.25 Sealing ring 1st 40.2 0.10 ÷ 0.25 Over Sealing ring 2nd 40.4 0.10 ÷ 0.25 Over Crankcase - crankshaft - connecting rod AXIAL PLAY CONNECTING ROD - CRANKSHAFT Name Description...
  • Page 15 Runner RST Purejet Characteristics PISTON - TEST PROBE Name Descrip Dimens Initials Quantit tion ions Piston Ø 12 0.002 ÷ +0.007 0.011 +0.012 Test Ø 12 0.002 ÷ probe +0.005 0.011 +0.001 ROD SMALL END - ROLLER CASING - TEST PROBE Name Descrip Dimens...
  • Page 16 Runner RST Purejet Characteristics Name Descrip Dimens Initials Quantit tion ions 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 -0.005 Roller Cat. 3 Ø...
  • Page 17 Runner RST 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 RST Purejet Characteristics CHAR - 12...
  • Page 19 INDEX OF TOPICS TOOL OOLING...
  • Page 20 Runner RST 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 RST 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 RST 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 RST 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 RST 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 RST 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 RST 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 RST 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 RST 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 RST 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 RST 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 RST Purejet Maintenance Maintenance chart EVERY 2 YEARS Action Brake fluid - change Coolant - change AT 1,000 KM Action Hub oil level - Check / Replace Oil mixer/throttle linkage - adjustment Steering - adjustment Brake control levers - greasing Brake fluid level - check Safety locks - check Electrics - Check...
  • Page 33 Runner RST Purejet Maintenance AT 15,000 KM , 45,000 KM Action Hub oil level - Check / Replace Spark plug - replacement Oil mixer/throttle linkage - adjustment Driving belt - replacement Brake control levers - greasing Brake pads - check condition and wear Brake fluid level - check Coolant level - check Transmission elements - lubrication...

  • Page 34: Spark Plug

    Runner RST Purejet Maintenance Action Brake fluid level - check Coolant level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrics - Check Headlight - adjustment check Tyre pressure and wear - check Vehicle and brake test - road test AT 60,000 KM Action Hub oil level - Check / Replace...
  • Page 35 Runner RST Purejet Maintenance Characteristic Electrode gap 0.6 ÷ 0.7 mm Recommended spark plug RG 6 YCA Locking torques (N*m) Spark plug: 11 ÷ 14 Nm Hub oil Check To check the hub oil level, proceed as follows: 1. Place the scooter on its stand on a level sur- face;...

  • Page 36: Air Filter

    Runner RST Purejet Maintenance OTHER MODELS BY THE MANUFACTURER, AND HAVE NO SPECIFIC FUNCTION FOR THIS MODEL. Recommended products AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Characteristic Rear hub oil Quantity: approx.
  • Page 37 Runner RST Purejet Maintenance transmissions After mounting the transmissions, check that they move perfectly within the sheath. - Lubricate the cable with the recommended prod- uct, applying a plastic bag as shown in the picture. - If the cable does not move perfectly due to pos- sible fraying replace both the cable and the sheath.

  • Page 38: Cooling System

    Runner RST Purejet Maintenance Mixer timing Use the transmission register to adjust, with the gas command released and the position of mixer lever as shown in the picture. N.B. TO VERIFY THE CORRECT TIMING OF THE MIXER IT IS NECESSARY TO REMOVE THE AIR CONDUIT OF THE TRANSMISSION COVER.

  • Page 39: Headlight Adjustment

    Runner RST Purejet Maintenance Headlight adjustment Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen;...
  • Page 40 Runner RST Purejet Maintenance MAIN - 10...
  • Page 41 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 42: Engine Overheating

    Runner RST 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 RST 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 RST Purejet Troubleshooting 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 RST Purejet Electrical system WIRING DIAGRAM 1. Magneto flywheel 2. Voltage regulator 3. Spark plug 4. high voltage coil 5 . Fuel injector 6. Air injector 7. Key switch 8. Fuse box: Fuse 1: General 20A Fuse 2: Horn and indicators 5A Fuse 3: Lights 5A 9.
  • Page 47 Runner RST Purejet Electrical system 17. Intermittence device for turn indicators 18. Left rear direction indicator light 19. Rear optical unit A. Parking light B. Stop light 20. Right rear direction indicator light. 21. Left front direction indicator light. 22. Front optical unit A.
  • Page 48 Runner RST Purejet Electrical system Ignition IGNITION 1. Magneto flywheel 2. Voltage regulator 3. Spark plug 4. high voltage coil 7. Key switch 8. Fuse box: Fuse 1: General 20A Fuse 2: Horn and indicators 5A Fuse 3: Lights 5A 9.
  • Page 49 Runner RST Purejet Electrical system Headlights and automatic starter section LIGHTS 7. Key switch 8. Fuse box: Fuse 1: General 20A Fuse 2: Horn and indicators 5A Fuse 3: Lights 5A 9. Battery 19. Rear optical unit A. Parking light B.
  • Page 50 Runner RST Purejet Electrical system Battery recharge and starting RECHARGE BATTERY AND STARTER 1. Magneto flywheel 2. Voltage regulator 7. Key switch 8. Fuse box: Fuse 1: General 20A Fuse 2: Horn and indicators 5A Fuse 3: Lights 5A 9. Battery 10.
  • Page 51 Runner RST Purejet Electrical system Level indicators and enable signals section CONSENSUS AND LEVEL INDICATOR 5. Fuel injector 6. Air injector 7. Key switch 8. Fuse box: Fuse 1: General 20A Fuse 2: Horn and indicators 5A Fuse 3: Lights 5A 9.

  • Page 52: Turn Signal Lights

    Runner RST Purejet Electrical system 34. Electronic central unit Turn signal lights TURN INDICATORS AND HORN 7. Key switch 8. Fuse box: Fuse 1: General 20A Fuse 2: Horn and indicators 5A Fuse 3: Lights 5A 9. Battery 15. Horn 16.
  • Page 53 Runner RST Purejet Electrical system Instruments and warning lights control board INSTRUMENT UNIT Specification Desc./Quantity + Battery + permanent power supply Ground lead Grounding for phonic wheel Power supply to phonic wheel Phonic wheel signal Instrument lighting enabling temperature instrument ELE SYS - 9...
  • Page 54 Runner RST Purejet Electrical system Specification Desc./Quantity Not connected Rpm indicator signal Coolant temperature indicator Fuel level sensor High-beam warning light Right direction indicator Left direction indicator Low-oil warning light Low fuel warning light Oil light check outlet Injection warning light Not connected Checks and inspections Battery recharge circuit...

  • Page 55: Starter Motor

    Runner RST 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 56 Runner RST 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 57 Runner RST Purejet Electrical system Turn signals system check The turn indicator circuit is controlled by an inter- mittent device. If there are any problems with turn indicator circuit, check: - 5A fuse indicated in the photo, removing the bat- tery cover.
  • Page 58 Runner RST Purejet Electrical system If there are problems with the lighting system, check: - Efficiency of the lights - 5A fuse indicated in the figure, removing the battery cover. - Check that the YELLOW-BLACK wires of the light switch is under a voltage of +12V - Check the efficiency of the light switch - Ensure the presence of a ground wire to the light- bulb holders.
  • Page 59 Runner RST Purejet Electrical system - ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRE- SPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.
  • Page 60 Runner RST Purejet Electrical system WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE. Normal charging on the bench is done with the specific battery charger (single or multiple), positioning the battery charger selector on the type of battery to recharge at a current of 0.9A for around 6 ÷...
  • Page 61 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 62 Runner RST 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 RST 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 RST Purejet Engine from vehicle - Remove the electric connectors from the fuel and air injector - Remove the electric connector from the throttle body - Remove the fastening of the wiring clamp to the thermostat clamp by removing the screw indicated in photo ENG VE - 4...
  • Page 65 Runner RST 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 coolant temperature sensor con- nector...
  • Page 66 Runner RST Purejet Engine from vehicle - Remove the cooling system lines from the engine and discharge the fluid - Remove the lower shock absorber clamp - Use two 17 mm Allen wrenches to remove the engine/swinging arm fixing pin - Remove the oil mixer pipe from the tank - To refit, perform the operations in the reverse direction and ensure that the electric wiring is properly fixed to components such as: air injector, fuel injector, throttle body, generator, coolant temperature...
  • Page 67 INDEX OF TOPICS NGINE...

  • Page 68: Automatic Transmission

    Runner RST 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 69: Inspecting The Clutch Drum

    Runner RST 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 70 Runner RST 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...
  • Page 71 Runner RST 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...
  • Page 72 Runner RST 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 73: Refitting The Driven Pulley

    Runner RST 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 74 Runner RST Purejet Engine Lithium grease with NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 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 75: Removing The Driving Pulley

    Runner RST Purejet Engine 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 ÷ 44 N·m Drive-belt - Make sure the driving belt is not damaged and does not have cracks in the toothed grooves.
  • Page 76 Runner RST Purejet Engine • Remove the transmission cover • Lock the engine pulley using the specific tool. • Remove the central nut with washer, remove the plastic fan. • Remove the fixed half-pulley. • Remove the belt and washer and remove the mobile half pulley with its bushing, being careful of the rollers fitted on it.
  • Page 77 Runner RST Purejet Engine - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inside diameter «A». - Measure outside diameter «B» of the pulley slid- ing bushing shown in the figure. CAUTION DO NOT LUBRICATE OR CLEAN THE BUSH- ING.
  • Page 78 Runner RST Purejet Engine 020451Y Start-up crown lock Locking torques (N*m) Driving pulley nut 40÷ 44* End gear 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. •...
  • Page 79 Runner RST 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 80 Runner RST 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.

  • Page 81: Removing The Stator

    Runner RST 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 82 Runner RST 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 83 Runner RST 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 84: Removing The Cylinder Head

    Runner RST 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 85 Runner RST 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 86 Runner RST 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 •...

  • Page 87: Inspecting The Small End

    Runner RST 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 88 Runner RST 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 89: Removing The Piston

    Runner RST 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 90 Runner RST 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. •...
  • Page 91 Runner RST 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 •...
  • Page 92 Runner RST 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 93 Runner RST 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 94 Runner RST 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 Removing the driving pulley Cylinder assy. and timing system Removing the driven pulley Removal Splitting the crankcase halves...
  • Page 95 Runner RST 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 96 Runner RST 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 97 Runner RST 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 98 Runner RST 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 99 Runner RST 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 100 Runner RST 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 101 Runner RST Purejet Engine Characteristic Axial clearance with warm crankcase 0.10 ÷ 0.12 mm Axial clearance with cold crankcase 0.06 to 0.08 mm Limit value with cold crankcase 0.02 ÷ 0.03 mm Air compressor Removal Removing air compressor - 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...
  • Page 102 Runner RST Purejet Engine Overhaul Check air compressor - 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 103 Runner RST Purejet Engine - Remove the flywheel cover. - Turn the crankshaft to check that the eccentric track exhibits no unusual wear or signs of over- heating. Refitting Refit air compressor - Place the shaft with the eccentric at its lower dead point.
  • Page 104 Runner RST Purejet Engine - Refit the throttle body manifold. - Refit the flywheel cover. Lubrication 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.

  • Page 105: Oil Pump

    Runner RST Purejet Engine - Lubricate bearings and connecting rod head us- ing 2T oil. - Refit the thermal unit - Refit the compressor - Refit the throttle body - Refit the flywheel - stator - Refit the mixer - Refit the driven pulley - Refit the driving pulley Oil pump Refitting...
  • Page 106 Runner RST Purejet Engine ENG - 40...
  • Page 107 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 108: Removing The Front Wheel

    Runner RST Purejet Suspensions Front Removing the front wheel - Remove the fixing nut from the wheel axle on the left side of the vehicle. - Loosen the fixing screw of the wheel axle clamp and remove it. Front wheel hub overhaul - Remove the front wheel - Keep the wheel level by means of two wooden wedges...
  • Page 109 Runner RST Purejet Suspensions - Remove the internal spacer - Use appropriate handle, adaptor and guide and hit with a mallet to extract the bearing and the spacer bushing on the brake disk side; insert han- dle on the side the rpm indicator detects move- ment, as shown in the photo Specific tooling 020376Y Adaptor handle...

  • Page 110: Removing The Rear Wheel

    Runner RST Purejet Suspensions Removing the front wheel Refitting the front wheel - When refitting, pay attention in repositioning the odometer drive correctly. Locking torques (N*m) Wheel fixing nut 40 to 50 N.m Rear 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.
  • Page 111 Runner RST Purejet Suspensions Refitting When refitting, tighten the shock absorber/frame anchorage nut and the shock absorber/engine pin at the prescribed torque. 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-...
  • Page 112 Runner RST Purejet Suspensions Stand screw torque 18.5 to 19 Nm SUSP - 6...
  • Page 113 INDEX OF TOPICS INJ PJ PURE JET INJECTION...
  • Page 114 Runner RST 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 115 Runner RST 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 116: Troubleshooting

    Runner RST 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 117 Runner RST 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.
  • Page 118 Runner RST 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.
  • Page 119 Runner RST 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 120 Runner RST 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 121 Runner RST 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 122 Runner RST 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 123 Runner RST 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 124 Runner RST Purejet pure jet injection cpu power circuit INJECTION ECU POWER SUPPLY CIRCUIT Specification Desc./Quantity Injection warning light Fuse 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 125 Runner RST Purejet pure jet injection 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. 5- Connect the diagnostic tester of scooter.
  • Page 126 Runner RST Purejet pure jet injection 15- Continue checking the charger system GO TO point 17 16- The ECU supplies meet specs. 17- Check all electrical installation connections for any possible problems related to loosening or oxi- dation. GO TO point 20 18- Check the main supply.
  • Page 127 Runner RST Purejet pure jet injection 25- The supply meets specs. 26- Check the efficiency of the 20A 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 128 Runner RST Purejet pure jet injection - 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 meets specs.
  • Page 129 Runner RST Purejet pure jet injection 1 - 17 = 0 Volt (switch on «OFF») YES point 45 NO point 44 44- The fuse is burnt again. 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 130 Runner RST 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 131 Runner RST 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. throttle position sensor circuit (T.P.S.) TERMINALS: 16 (-) - 18 (+) CONDITIONS: Key switch set to «ON»...
  • Page 132 Runner RST 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 133 Runner RST 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 134 Runner RST 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 135 Runner RST 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 136 Runner RST 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 137 Runner RST 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 138 Runner RST 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 139 Runner RST 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 140 Runner RST 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 141 Runner RST 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 142 Runner RST 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 143 Runner RST 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 144 Runner RST 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 145 Runner RST 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 20A fuses 3 Air injector 4 Fuel injector 5 H.V. coil 6 Voltage regulator 7 Battery 12V 9Ah A+ under panel...
  • Page 146 Runner RST Purejet pure jet injection are indicated to the driver by the injection light lighted steady. In addition, to safeguard the safety of the vehicle, the injector power supply is interrupted and its functionality is not automatically reset, thereby avoiding the possibility of use with lost ignitions.
  • Page 147 Runner RST Purejet pure jet injection CHECKING THE ELECTRIC CIRCUIT 1. Connect the interface wiring. Do not connect the ECU. Disconnect the connector of the H.V. coil primary. GO TO point 2 Specific tooling 020481Y Control unit interface wiring 2. Check that there is a positive battery voltage to the connector supplying the primary with the switch in any position.
  • Page 148 Runner RST 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 149 Runner RST 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 150 Runner RST 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 151 Runner RST 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 152 Runner RST 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 153 Runner RST 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 154 Runner RST Purejet pure jet injection COMPONENTS LAYOUT 1 ECU 2 20A fuses 3 Air injector 4 Fuel injector 5 H.V. coil 6 Voltage regulator 7 Battery 12V 9Ah A+ under panel B To flywheel magneto The injection system integrated with the injection is inductive. Ignition is controlled based on two pa- rameters: - Ignition advance - Core dwelling time (DWELL)
  • Page 155 Runner RST Purejet pure jet injection 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". The air injector and relevant circuit are currently efficient.
  • Page 156 Runner RST 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 157 Runner RST 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 158 Runner RST 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 159 Runner RST Purejet pure jet injection enables the circuit to be bled and the old boiled fuel to be drained from inside the injector mounting . Successive pump control will be in combination with the presence of the rpm phase signal. This guar- antees the safety of the vehicle in case of an accident.
  • Page 160 Runner RST Purejet pure jet injection 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. 14- Fuel pump error in actual state. Proceed with the check on the fuel pump supply circuit. 15- Connect the interface wiring.
  • Page 161 Runner RST Purejet pure jet injection 21- Restore the wiring. GO TO point 20 22 - Check the fuel pump control line negative in- sulation. 1 - 14 = 1 MOhm YES point 24 NO point 23 23- Restore the wiring. GO TO point 22 24- Check the fuel pump winding continuity.
  • Page 162 Runner RST Purejet pure jet injection 28- Especially in case an error is verified in the «occurred» or «stored» state, repeat activation of the pump several times in order to distinguish any faults deriving from a manifold that is not perfectly effi- cient.
  • Page 163 Runner RST Purejet pure jet injection A+ under panel B To flywheel magneto The injection system integrated with the injection is inductive. Ignition is controlled based on two pa- rameters: - Ignition advance - Core dwelling time (DWELL) The ignition advance curve is optimised according to the engine rpm and load, perceived through the TPS1 and TPS2 signals.
  • Page 164 Runner RST Purejet pure jet injection 1. Disconnect the interface wiring. Omit the con- nection to the ECU. Disconnect the air injector connector. GO TO point 2 2. Check the battery positive voltage to the blue lead (1) of the fuel injector power supply connec- tor.
  • Page 165 Runner RST Purejet pure jet injection 7. Restore the wiring GO TO point 6 8. Check the fuel injector control line negative in- sulation 1 - 3 > or = 1Ohm NO point 9 YES point 10 9. Restore the wiring GO TO point 8 10.
  • Page 166 Runner RST Purejet pure jet injection 16. The fuel injector control circuit is efficient. While the engine is running, the opening time of the fuel injector can be displayed through the indication given in the "PARAMETERS" menu of the scooter diagnostic tester.
  • Page 167 Runner RST Purejet pure jet injection efficiency of the automatic intake bleeding. Downstream of the pump is the circuit designed to operate under pressure. The connection between the pump and the injector mounting consists of a preformed plastic hose provided with quick-fit fittings. Before removing-attaching the fittings, follow the operations described in "ENGINE FROM THE VEHICLE"...
  • Page 168 Runner RST Purejet pure jet injection N.B. BEFORE INSTALLATION, CAREFULLY BLOW THE DUCTS OF THE SPECIAL TOOL. ANY IM- PURITY MAY DAMAGE THE FUEL INJECTOR. DETACH AND REATTACH THE QUICK-FIT FIT- TINGS AS PRESCRIBED. Specific tooling 020616Y Fuel pressure control kit 4.
  • Page 169 Runner RST Purejet pure jet injection 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 170 Runner RST 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 171 Runner RST 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 172 Runner RST 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 173 Runner RST 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 174 Runner RST Purejet pure jet injection INJ PJ - 62...
  • Page 175 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 176: Rear Brake Calliper

    Runner RST 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 177 Runner RST Purejet Braking system ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED. Refitting Insert in the calliper body: - sealing rings (1-2); - small pistons(3); - place the OR seal in a calliper body (4). - Join the internal and external body with the as- sembly bolts.

  • Page 178: Front Brake Disc

    Runner RST Purejet Braking system Removal - Remove muffler and wheel. - Remove both support calliper clamps, without disconnecting the hydraulic union. - To allow the calliper to exit from its housing, de- tach the spring which blocks the hydraulic line under the transmission protection crankcase.

  • Page 179: Front Brake Pads

    Runner RST Purejet Braking system Refitting - On refitting, position the disc correctly, making sure to turn it in the right direction and apply medium threadblock. Recommended products Loctite 242 product description Apply LOCTITE medium type 242 threadlock Locking torques (N*m) Disc tightening screw 6 ÷...
  • Page 180 Runner RST Purejet Braking system Fill Front - With the bleed valve closed, fill the system to the maximum level with brake fluid. - Loosen the bleed valve. - Apply the tube of the specific tool to the bleed valve. To bleed the circuit you must supply the reservoir constantly with oil while pumping the Mityvac pump until there is no more air leaving the circuit.
  • Page 181 Runner RST Purejet Braking system THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE OIL ON IT. Specific tooling 020329Y MityVac vacuum-operated pump Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid Locking torques (N*m) Oil bleed screw 8÷12...
  • Page 182 Runner RST Purejet Braking system 7. Gasket. 8 - Spring CAUTION - THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAK- ING EFFICIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY SOL- VENT.
  • Page 183 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 184 Runner RST 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 185 Runner RST 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 186 Runner RST 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 187 Runner RST 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 188 Runner RST 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 189 INDEX OF TOPICS CHAS HASSIS...
  • Page 190 Runner RST Purejet Chassis Seat Lift the saddle and remove the screws indicated in the photograph Rear handlebar cover - Remove the front handlebar cover - Remove the 3 screws indicated in the figure -After disconnecting the wiring remove the rear handlebar.
  • Page 191 Runner RST Purejet Chassis -Remove the rear-view mirrors. -Remove the two screws shown in the figure, and at the same time disconnect the fitting in the upper part of the handlebar cover. Pull the front part up- wards so as not to damage the fittings made of plastic.
  • Page 192 Runner RST Purejet Chassis - Remove the ring nut of the fuel tank cap by un- screwing the 3 screws indicated in the photograph. - Remove the filling hole unit of the fuel tank by loosening the 3 screws <A> indicated in the pho- tograph and the metal clamp.
  • Page 193 Runner RST Purejet Chassis - Remove the front shield after disconnecting the wiring of the front headlight assembly and of the taillights. Assembly following the procedure in reverse or- der. See also Front central cover Knee-guard - Remove the central chassis cover. - Remove the shield central cover and remove the supporting screws for the expansion tank.
  • Page 194 Runner RST Purejet Chassis Front central cover Removing the ignition key-switch when on *off* - Remove the front shield and back shield. - Insert a small awl in the groove shown in the photo and pry up until the clamp is removed. - Remove the lock body.
  • Page 195 Runner RST Purejet Chassis Front wheel housing • Remove the front fork; • Unscrew the central stud of the wheel well at the frame; • Disconnect the brake pipe to the pump and pull it out;; • Remove the odometer transmission.. Taillight assy.
  • Page 196 Runner RST Purejet Chassis Side fairings The side fairing consists of 3 parts as described in the figure. Fairing A - Remove the 4 screws indicated in the figure and take out the casing. Fairing B - Remove fairing A - Remove the passenger handles.
  • Page 197 Runner RST Purejet Chassis Fairing C - Remove the central chassis cover. - Remove the lateral fairings A and B. - Remove the fairing by pulling it upwards. Helmet bay - Remove the battery. - Remove the saddle. - Remove the rear central cover. - Remove the side panels - Remove the mix.

  • Page 198: Fuel Tank

    Runner RST Purejet Chassis Fuel tank - Remove the central chassis cover. Remove the side fairings and the helmet compart- ment. - Remove the screw <C> indicated in the figure at both sides. - Remove the bolt <A> and loosen the nut <B>in- dicated in the figure.
  • Page 199 Runner RST Purejet Chassis Radiator fan - Set up a receptacle to collect coolant. - Remove the fuel tank. - Loosen the clamps and disconnect the 4 lines from the radiator. - Remove the radiator by the 4 studs shown in the figure.

  • Page 200: Lower Cover

    Runner RST Purejet Chassis Front central cover - Remove the Gilera emblem placing a screwdriver in the emblem right groove. - Remove the screw indicated in the photograph and remove the cover by pulling it upwards. Battery Dopo aver rimosso il coperchio batteria installare la batteria rispettando le polarità...
  • Page 201 Runner RST Purejet Chassis CHAS - 13...
  • Page 202 Runner RST Purejet Chassis CHAS - 14...
  • Page 203 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 204 Runner RST Purejet Pre-delivery Aesthetic inspection Appearance checks: - 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 *...
  • Page 205 Runner RST Purejet Pre-delivery 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 OPEN FLAMES OR SPARKS AWAY FROM THE BATTERY DURING CHARGING.
  • Page 206 Runner RST Purejet Pre-delivery Static test - Tyre pressure - Operation of all locks. - Fitting mirrors and accessories. - Equipment, instruction manual, warranty certificate and customer assistance document. CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
  • Page 207 INDEX OF TOPICS TIME...
  • Page 208 Runner RST Purejet Time Engine ENGINE Code Action Duration 001001 Eng. from frame - Removal and refit 003057 Engine retainer - Tighten nuts TIME - 2...
  • Page 209 Runner RST Purejet Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase- Replace- ment TIME - 3...
  • Page 210 Runner RST 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 - 4...
  • Page 211 Runner RST Purejet Time Cylinder assy. PISTON - CYLINDER - TEST PROBE ASSEMBLY Code Action Duration 001002 Cylinder-Piston - Replace- ment 001107 Cylinder/piston - Service / clean TIME - 5...
  • Page 212 Runner RST Purejet Time Cylinder head assy. INJECTOR MOUNTING 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...
  • Page 213 Runner RST Purejet Time INLET MANIFOLD - HEAD Code Action Duration 001056 Head gasket - Replacement 001013 Inlet manifold- Replacement 003056 Head/cylinder - Nuts tighten- TIME - 7...
  • Page 214 Runner RST 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 - 8...
  • Page 215 Runner RST Purejet Time Oil pump OIL PUMP Code Action Duration 001019 Mixer belt - Replacement 001028 Mix gear movement- Re- placement 001018 Mixer - Replacement TIME - 9...
  • Page 216 Runner RST 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 - 10...
  • Page 217 Runner RST 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 - 11...
  • Page 218 Runner RST Purejet Time Water pump WATER PUMP Code Action Duration 001113 Water pump - Replacement 001062 Pump command shaft - Re- moval and refit TIME - 12...
  • Page 219 Runner RST Purejet Time Starter motor STARTER Code Action Duration 001017 Starter pinion - Replacement 001020 Starter motor - change 005045 Starter cable assembly - Re- placement TIME - 13...
  • Page 220 Runner RST Purejet Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - Replace- ment 001058 Flywheel - Replacement 001067 Stator - Removal and refit TIME - 14...
  • Page 221 Runner RST Purejet Time Belt cooling duct BELT REFRIGERATION TUBE Code Action Duration 001132 Transmission air intake pipe - Replacement 001131 Transmission air intake - Re- placement TIME - 15...
  • Page 222 Runner RST Purejet Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body TIME - 16...
  • Page 223 Runner RST Purejet Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement TIME - 17...

  • Page 224: Air Cleaner

    Runner RST 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 - 18...
  • Page 225 Runner RST Purejet Time Mudguard REAR AND FRONT MUDGUARD Code Action Duration 004009 Rear mudguard - Replace- ment 004002 Front mudguard - Replace- ment 006003 Mudguard - Painting TIME - 19...
  • Page 226 Runner RST Purejet Time Radiator RADIATOR Code Action Duration 007002 Water cooler - Replacement 007003 Coolant delivery and return pipe - Replacement 001052 Coolant - Replacement TIME - 20...
  • Page 227 Runner RST Purejet Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Re- moval and refit TIME - 21...
  • Page 228 Runner RST 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 - 22...
  • Page 229 Runner RST 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 230 Runner RST 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 231 Runner RST Purejet Time Seat SEAT Code Action Duration 004003 Saddle - Replacement compressore aria AIR COMPRESSOR Code Action Duration 001168 Air compressor - Replace- ment TIME - 25...

  • Page 232: Brake Callipers

    Runner RST Purejet Time Code Action Duration 004160 Compressed air hose - Re- placement Brake callipers 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 233 Runner RST Purejet Time FRONT BRAKE CALLIPER Code Action Duration 002039 Front brake calliper - Remov- al and refit 002040 Front brake calliper - Check 002021 Front brake line - Removal and refit 002047 Frt. brake fluid and bleeding circuit- Replacement 003070 Front brake pads / Shoes - Check wear...
  • Page 234 Runner RST Purejet Time Rear wheel axle REAR WHEEL AXLE Code Action Duration 001010 Reduction gear-Service 003065 Gear box oil - Replacement 004145 Rear wheel axle - Replace- ment TIME - 28...
  • Page 235 Runner RST Purejet Time Front suspension FRONT FORK Code Action Duration 003051 Complete fork - Replacement 003041 Fork stanchion - Replace- ment 003048 Oil seal fork - Replacement 003039 Fork leg mandrels - Replace- ment 003010 Front suspension - Service TIME - 29...

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