Gilera SMT RCR 633793 Service Station Manual
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Gilera SMT RCR 633793 Service Station Manual

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SERVICE STATION MANUAL
633793 ÷ 633800
SMT RCR

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Summary of Contents for Gilera SMT RCR 633793

  • Page 1 SERVICE STATION MANUAL 633793 ÷ 633800 SMT RCR...
  • 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 service station manual has been drawn up by Piaggio & C. S.p.A. to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated 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 BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Vehicle Identification

    SMT RCR Characteristics Vehicle identification Chassis prefix The chassis registration number is stamped on the right side of the headstock. RCR: ZAPG11D1A SMT: ZAPG12D1A Dimensions and mass SIZES Specification Desc./Quantity Width 805 mm Length 1972 mm Max. height 1125 mm Wheelbase 1,355 mm CHAR - 7...
  • Page 8 SMT RCR Characteristics SIZES Specification Desc./Quantity Width 805 mm Length 2036 mm Max. height 1222 mm Wheelbase 1,355 mm CHAR - 8...

  • Page 9: Electrical System

    SMT RCR Characteristics Engine NGINE Specification Desc./Quantity Type single-cylinder, two-stroke Bore 40 mm Stroke 39.88 mm Cubic capacity 49 cm³ Compression ratio 11.5 :1 Carburettor Dell'Orto PHVA-17.5 with manual starter Engine idle speed 1900 ± 100 rpm Air filter sponge impregnated with a mixture 50% oil (Selenia Air Filter Oil) and 50% unleaded petrol.

  • Page 10: Wheels And Tyres

    SMT RCR Characteristics Frame and suspensions HASSIS AND SUSPENSIONS Specification Desc./Quantity Chassis diagonal twin spar frame. Front suspension: Hydraulic fork and centred axle. Rear suspension: Swinging with hydraulic progressive shock absorber. Brakes RAKES Specification Desc./Quantity Front wheel brake: Hydraulic disc Ø...
  • Page 11 SMT RCR Characteristics NGINE VEHICLE Name Torque in Nm Shock absorber to chassis upper attachment 30-40 Shock absorber to chassis lower attachment 55-65 Lower arm to shock absorber chassis clamp 55-65 Arm to chassis clamp 55-65 Arm to suspension clamp 55-65 Oscillating fork 70-80...
  • Page 12 SMT RCR Characteristics Product Description Specifications PARAFLU MOTO RIDER coolant Ready to use monoethylene glycol anti- freeze fluid, CUNA NC 956-16 AGIP GEAR 80W-90 gearbox oil SAE 80W-90 oil complying with API GL4 specifications CHAR - 12...
  • Page 13 INDEX OF TOPICS TOOL OOLING...
  • Page 14 SMT RCR Tooling TOOLS Stores code Description 00H0530004.1 Clutch locking tool 00H0530015.1 Engine opening tool 00H0560032.1 Crankshaft gear extractor 001330Y Tool for fitting steering seats 002465Y Pliers for circlips 020004Y Punch for removing fifth wheels from headstock 020074Y Support base for checking crankshaft alignment 020150Y Air heater support...
  • Page 15 SMT RCR Tooling Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger 020357Y 32 x 35 mm adaptor 020358Y 37x40-mm adaptor TOOL - 15...
  • Page 16 SMT RCR Tooling Stores code Description 020363Y 20 mm guide 020376Y Adaptor handle 020412Y 15 mm guide 020425Y Punch for flywheel-side oil seal 020439Y 17 mm guide 020441Y 26 x 28 mm adaptor TOOL - 16...
  • Page 17 SMT RCR Tooling Stores code Description 020455Y 10-mm guide 020456Y Ø 24 mm adaptor 020544y Pliers for clamps 020565Y Flywheel lock calliper spanner 020581Y Flywheel extractor TOOL - 17...
  • Page 18 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 19: Maintenance Chart

    SMT RCR Maintenance Maintenance chart 1000 K FTER Action Coolant- Change Air filter - cleaning Odometer gear - greasing Steering - Check Brake control levers - greasing Brake pads - check Transmission chain - greasing Tension transmission chain - check Safety locks - check Front fork- Check Electrical system and battery - check...
  • Page 20 SMT RCR Maintenance Action Tyres pressure - Check Oil filter -Replacement Fuel and oil hoses - Replacement Vehicle and brake test - road test Engine oil - change Spark plug/electrode gap - replacement Carburettor - Adjustment Clutch control lever - Adjustment 15,000;...
  • Page 21 SMT RCR Maintenance Carburettor KEY: 1. Starter 2. Idle air set screw 3. Idle speed set screw 4. Throttle valve spring 5. Throttle valve tapered pin 6. Throttle valve 7. Carburettor body 8. Pin 9. Minimum nozzle 10. Float 11. Starter nozzle 12.
  • Page 22 SMT RCR Maintenance - The throttle valve should slide freely in the mixture chamber. Replace it in case of excessive clearance due to wear. - If there are wear marks in the mixer chamber causing inadequate tightness or a free valve slide (even if it is new), replace the carburettor.

  • Page 23: Spark Plug

    SMT RCR Maintenance - With the engine at 3000 rpm, check that the line (1) on the magneto flywheel is aligned with the notch on the crankcase (2). ECHNICAL SPECIFICATIONS Specification Desc./Quantity Timing 22º at 3000 rpm Advance 1.8º at 3000 rpm Spark plug - Clean the deposits between the two electrodes.

  • Page 24: Air Filter

    SMT RCR Maintenance Air filter - To reach the filtering element, remove the saddle and the right side fairing. - Afterwards, remove the 4 screws on the air filter cover shown in the photograph. Cleaning - Wash the sponge with water and mild soap. - Dry it with a clean cloth and short blasts of com- pressed air.
  • Page 25 SMT RCR Maintenance - To adjust the mixer, operate on the correspond- ing set screw shown in the figure. - The correct oil flow rate is obtained by aligning the two references shown in the figure. Drive chain adjustment It is convenient to check chain tension every 1000 km and, if required, adjust and lubricate the chain.

  • Page 26: Braking System

    SMT RCR Maintenance Braking system Rear brake fluid Front brake oil level check Proceed as follows: - Place the scooter upright. - Check the fluid level through the references on the brake oil reservoir body. Topping up brake fluid Proceed as follows: - Unscrew the reservoir cap, remove the gasket and top-up using only the specified fluid but never exceed the maximum level.
  • Page 27 SMT RCR Maintenance CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THE ABOVE MENTIONED FLUID EVERY 2 YEAR. Recommended products AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 Braking system fluid Front brake oil level check Proceed as follows:...

  • Page 28: Headlight Adjustment

    SMT RCR Maintenance CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THE ABOVE MENTIONED FLUID EVERY 2 YEAR. Recommended products AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based spray grease with NLGI 2;...

  • Page 29: Gearbox Oil

    SMT RCR Maintenance Direct the front headlight by operating on the screw indicated in the photograph. Gearbox Oil - Warm the engine up to the regular operating tem- perature - Remove the oil filler cap (3) - Remove the oil drainage plug from the right crankcase cover (1) - Remove the oil drainage plug from the central section of the crankcase (2)
  • Page 30 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 31 SMT RCR Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel nozzles or cock clogged or dirty. Remove, wash with solvent and dry with com- pressed air. Excess of deposits on the cylinder ports and in the combustion Descale the thermal group. chamber.

  • Page 32: Engine Overheating

    SMT RCR Troubleshooting ENGINE TENDS TO STOP AT TOP SPEED Possible Cause Operation Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air Dirty carburettor Wash the carburettor with solvent and dry with compressed air Spark plug faulty or dirty.
  • Page 33 SMT RCR Troubleshooting Possible Cause Operation Brake noise Check the pads and the front brake disc. If exces- sive wear or scoring is found, replace when nec- essary. Pads worn Check the brake pads for wear. Electrical system Battery ATTERY Possible Cause Operation Battery...
  • Page 34 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 35 SMT RCR Electrical system 1. Electronic ignition device 2. Spark plug 3. Voltage regulator 4. Magneto flywheel 5. Key switch 6. Main fuse 7. Battery 8. Horn 9. Horn button 10. Electric fan pre-installation 11. Rear brake STOP button 12. Front brake STOP button 13.
  • Page 36 SMT RCR Electrical system 20. Light switch 21. Instrument panel A. Oil warning light B. Temperature warning light C. High-beam warning light D. Turn indicator warning light E. Low fuel warning light F. Instrument panel bulb 22. Timer 23. Engine temperature warning light control 24.
  • Page 37 SMT RCR Electrical system - Disconnect the electrical connections and re- move the switch/lock unit. Conceptual diagrams Ignition 1. Electronic ignition device 2. Spark plug 4. Magneto flywheel 5. Key switch ELE SYS - 37...
  • Page 38 SMT RCR Electrical system Headlights and automatic starter section 3. Voltage regulator 4. Magneto flywheel 5. Key switch 15. Tail lights/stop light bulbs 18. High-beam/low-beam bulb 20. Light switch 21. Instrument panel A. Oil warning light B. Temperature warning light C.
  • Page 39 SMT RCR Electrical system Battery recharge and starting 3. Voltage regulator 4. Magneto flywheel 6. Main fuse 7. Battery ELE SYS - 39...
  • Page 40 SMT RCR Electrical system Level indicators and enable signals section 3. Voltage regulator 5. Key switch 6. Main fuse 7. Battery 21. Instrument panel A. Oil warning light B. Temperature warning light C. High-beam warning light D. Turn indicator warning light E.

  • Page 41: Turn Signal Lights

    SMT RCR Electrical system Turn signal lights 3. Voltage regulator 4. Magneto flywheel 5. Key switch 6. Main fuse 7. Battery 8. Horn 9. Horn button 13. Turn indicator switch 14. Left turn rear indicator bulb 16. Right turn rear indicator bulb 17.
  • Page 42 SMT RCR Electrical system E. Low fuel warning light F. Instrument panel bulb Checks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all re- place the control unit by another one in operating conditions.
  • Page 43 SMT RCR Electrical system - Check the resistance of the secondary winding of the high voltage coil (resistance between points A and B) WARNING IF THE READINGS OF THE SECONDARY WINDING AND THE MAGNETO FLYWHEEL ARE RIGHT, REPLACE THE COIL. Electric characteristic Resistance 5 - 6 kOhm...
  • Page 44 SMT RCR Electrical system - Check that the resistance between the terminals and the earth complies with the values indicated in the table. Lights list BULBS Specification Desc./Quantity Front headlamp bulbs 12V. 35/35 W. Type: Twin filament light/stop bulb: 12 V, 21/5 W Type: Twin filament Turn indicators bulb: 12 V, 10 W...
  • Page 45 SMT RCR Electrical system 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal capacity of the battery -Duration of the charge: 5 h WARNING -WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
  • Page 46 SMT RCR Electrical system 1 Hold the vertical tube 2 Look at the level 3 The float must be freed Battery maintenance The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are: 1) Check the level of the electrolyte The electrolyte level must be checked frequently and must reach the upper level.

  • Page 47: Battery Installation

    SMT RCR Electrical system 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 ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY.
  • Page 48 TY MUST NOT EXCEED 0.5 ÷ 1 A. OTHERWISE, THE BAT- TERY WOULD BE SERIOUSLY DAMAGED. BATTERIES CONTAIN VERY ENVIRONMENTAL DANGER- OUS SUBSTANCES. FOR BATTERY REPLACEMENT, CONTACT AN AUTHORISED PIAGGIO-GILERA SERVICE CENTRE, AS THEY ARE EQUIPPED FOR THE DISPOSAL IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY. ELE SYS - 48...
  • Page 49 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 50 SMT RCR Engine from vehicle Exhaust assy. Removal - Remove the left side fairing - Remove the screws fixing the muffler to the cyl- inder - Remove the screws fixing the silencer to the muf- fler - Remove the retainer fixing the silencer to the chassis - Slide off the muffler Removal of the engine from the vehicle...
  • Page 51 SMT RCR Engine from vehicle - Remove the exhaust pipe and the silencer. - Remove the cooling rubber pipe connecting the water pump to the radiator. - Get a container to collect the coolant. - Remove the following electric wires: •...
  • Page 52 SMT RCR Engine from vehicle - Remove the cable from the clutch lever. - Before removing the cable, fully loosen the set screw of the lever-hand grip unit. - Remove the oil pump cover and disconnect the metal cable and the hose connecting the oil res- ervoir to the mixer.
  • Page 53 SMT RCR Engine from vehicle - Remove the drive chain operating on the false mesh shown in the photograph. - Note the correct position of the drive chain upon refitting. - Remove the clamps fixing the engine to the chas- sis, indicated in the photograph.
  • Page 54 SMT RCR Engine from vehicle - Remove the engine from the chassis by pulling and rotating it slightly. ENG VE - 54...
  • Page 55 INDEX OF TOPICS NGINE...
  • Page 56 SMT RCR Engine Flywheel and starting Removing the flywheel magneto - Remove the left rear cover - Detach the gear pedal - Undo the three fixing screws and remove the crankcase left cover - Lock the magneto flywheel with the aid of the specific calliper spanner and remove the flywheel fixing nut Specific tooling...
  • Page 57 SMT RCR Engine - Undo the three fixing screws and remove the sta- tor from the crankcase Refitting the flywheel magneto - Align the symbol (1) on the stator with the centre of the arrow (2) on the crankcase and fix it with 3 screws - Connect the stator cables with the high voltage coil and fix them to the chassis with the brackets...

  • Page 58: Removing The Cylinder Head

    SMT RCR Engine Cylinder assy. and timing system Removing the cylinder head Head fitting - To refit it, carry out the removal operations but in reverse order - Fit a new gasket between the head and the cylinder - Make sure the coupling surfaces are perfectly clean - Place the head on the cylinder and tighten the four stud bolts in two or three stages, tightening one stud bolt and afterwards the one that is diametrically opposite - Refit the thermoswitch and fit an adhesive gasket on the thread...
  • Page 59 SMT RCR Engine Removing the cylinder - piston assy. - Drain the coolant out of the system - Remove the cylinder head - Remove the cooling circuit rubber pipe between the cylinder and the water pump - Move the cylinder slowly upwards - Remove the base gasket - Put a piece of old cloth in the cylinder housing hole on the crankcase so that no object can fall in...
  • Page 60 SMT RCR Engine Inspecting the piston - Check the piston diameter following the perpen- dicular axis to the pin seat. Carry out measure- ments 15 mm away from the lowest circlip seat Characteristic Serviceability limit: 0.05 mm Inspecting the cylinder - Measure the gaps of the piston sealing circlips by placing a thickness gauge in the cylinder Characteristic...

  • Page 61: Removing The Piston

    SMT RCR Engine Removing the piston - Refit the piston sealing circlips - Fit a new base gasket - Refit the ball retainer at the rod small end being careful to lubricate the components with recom- mended oil - Refit the piston paying attention to the direction of the arrow indicated on the piston crown.
  • Page 62 SMT RCR Engine - Remove the engine from the chassis and rest it on the engine support - Remove the thermodynamic unit (cylinder head and piston) - Remove the magneto flywheel - Remove the main gear, the kick start and the gear selector lever - Remove the fixings screws of both crankcase halves located to the left of the engine...
  • Page 63 SMT RCR Engine - Fit the specific tool from the flywheel side wall - Remove the crankshaft after warming up the shaft seat at about 60° Specific tooling 00H0530015.1 Engine opening tool - Take out the selector guiding fork and the selec- - Take out the two gear shafts at the same time - Thoroughly clean and degrease the crankshaft and then inspect it...
  • Page 64 SMT RCR Engine - Use a dial gauge to check the clearance between the connecting rod and the crankpin on the X and Y axes as indicated in the photograph Characteristic Serviceability limit: 0.35 mm - Make sure that both half shafts are not scratched or abnormally worn - Use two dial gauges and a support as indicated in the photograph to check the deviation of both...
  • Page 65 SMT RCR Engine - Undo the screw of the gear selector lever (1) - Undo the screw of the drum control head (2) - Unscrew the drum control pin - Make sure that the selector shaft springs and the gear selector lever spring have been correctly fit- - Check that the selector shaft is not worn or dam- aged - Fit the parts following the removal procedures but...
  • Page 66 SMT RCR Engine - Fit the oil pump shaft following the removal op- erations but in reverse order - It is crucial to make sure that the washers are correctly fitted - Fit the bolts on the clutch cover - Fit a new gasket on the crankcase right cover - Make sure the faying surfaces of the crankcase and cover are clean and in good conditions - Align the tappet (1) with the clutch shaft on the...
  • Page 67 SMT RCR Engine - Fit the clutch control (only if it has been previously removed) - Fit the new gasket on the clutch shaft using the specific tools Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020412Y 15 mm guide - Fit the clutch cables, the clamp and the lever - Using a screwdriver, rotate the clutch shaft anti- clockwise and then fit the clutch lever with its...
  • Page 68 SMT RCR Engine - Clean and lubricate the main bearings - Replace them if there are signs of abnormal wear, distortions or friction - To remove the main bearing, use the specific tool as shown in the photograph after warming up the crankcase at about 90°...
  • Page 69 SMT RCR Engine - Take out the gears and the shim washers from the secondary shaft once the locks have been re- moved - Check the gear studs and clefts are not rounded or show signs of abnormal use - Check the secondary shaft rings for wear - Replace them if 25% of their surface is worn - Make sure that the secondary shaft roller bearing show no signs of wear.
  • Page 70 SMT RCR Engine - Thoroughly clean and degrease all the gearbox components, the selector and the shaft with a de- greasing agent - Refit the secondary shaft making sure all com- ponents are fitted correctly - Refit the gearbox unit in the crankcase (the main and the secondary shafts must be fitted at the same time) - First check the overall size of the secondary shaft...
  • Page 71 SMT RCR Engine - Remove the crankcase right cover - Undo the 5 screws fixing the clutch spring and lift the clutch internal cover - Remove the 3 clutch plates and the two steel discs - Straighten the bevelled washer - Lock the hub with the specific tool and unscrew the nut with a M17 wrench - Detach the locking washer and the star washer...
  • Page 72 SMT RCR Engine - Remove the clutch bushing shell (4) and the bushing washer (5) - Check the clutch spring - Measure the length of each spring when exten- Characteristic Spring serviceability limit: 31 mm - Check the clutch plate - Measure the thickness of each plate Characteristic Serviceability limit:...
  • Page 73 SMT RCR Engine Visually inspect in between the teeth. Replace the component if there are signs of thermal fatigue, reduced surface hardness or teeth irregular wear. Check the components of the clutch bell are in good conditions: - Clutch disc seats - Rivets and connecting plugs with crown gears - Main shaft lever coupling CAUTION...
  • Page 74 SMT RCR Engine 020565Y Flywheel lock calliper spanner Locking torques (N*m) Flywheel 35 ÷ 45 Nm Right cover - Remove the engine protective cover - Remove the rear brake pump - Detach the coupling connecting the radiator to the hydraulic pump and drain the coolant out of the cooling system - Detach the coupling connecting the hydraulic pump to the cylinder...
  • Page 75 SMT RCR Engine - Loosen the screws fixing the clutch shaft and re- move it - Undo the three screws fixing the hydraulic pump and remove it - Detach the gasket and clean off any rests of old gaskets that may be left on the coupling surfaces of the hydraulic pump - Lock the driving gear (1) - Unscrew the fixing nut (2) first and then the rotor...
  • Page 76 SMT RCR Engine - Remove the crankcase left cover - Lock the magneto flywheel with the specific tool Specific tooling 020565Y Flywheel lock calliper spanner - Lock the magneto flywheel and then loosen the main transmission gear fixing nut and the pump driving gear - Remove the hydraulic pump and the oil pump driving gear...

  • Page 77: Oil Pump

    - Fit the transmission discs with the visible circle on one of the clutch surfaces facing out - Fit the clutch internal cover with the Gilera logo in line with the visible notch on one of the clutch hub teeth...
  • Page 78 SMT RCR Engine Removal Oil pump removal - Remove the oil pump cover located on the engine crankcase - Remove the oil feed and delivery hoses from the pump by operating on the flexible clamps - Be careful to close the oil feed hose connected to the pump so that the oil reservoir does not get empty - Remove the pump opening control cable by op-...
  • Page 79 SMT RCR Engine Refitting - Fit the oil pump following the removal procedure but in reverse order - Operate on the set screw to align the reference notches on the pump control lever (2) with those on the pump body, without accelerating with the throttle control - Purge the oil system after fitting the oil pump Oil pump purging...
  • Page 80 SMT RCR Engine Removing the carburettor Reed valve - Remove the carburettor from the engine - Remove the reed valve and its gasket from the crankcase - Check that the valve petals are not damaged or distorted. Replace them if they are. - Remove the plate limiting reed opening by undo- ing the three screws fixing the reed support - Fit the valve following the removal procedure but...
  • Page 81 SMT RCR Engine - Remove the carburettor by releasing the clamps on the inlet manifold and the bellows connected to the air cleaner housing - Remove the fuel pipe from the carburettor, the mixer oil intake pipe and the fuel valve low-pres- sure pipe - Operating on the screw indicated in the photo- graph, remove the throttle valve and its tapered pin...
  • Page 82 SMT RCR Engine - Remove the air flow set screw as indicated in the photograph - Remove the carburettor float chamber - Remove the float by operating the stem fixing it to the carburettor with a very thin pin - Remove the maximum nozzle, the minimum noz- zle and the starter nozzle Refitting the carburettor - Thoroughly clean all the carburettor components...
  • Page 83 SMT RCR Engine - Use scales to check the float weight. Weight: 3.5 - Replace the float if higher weight values are found - Make sure the tapered pin is in good conditions. Replace it if damaged or distorted - Make sure the starter control piston is in good conditions - Replace it if it shows signs of abnormal wear - Check that the calibration of the nozzles is ade-...
  • Page 84 SMT RCR Engine - Check that the lock is correctly positioned on the tapered pin notch - The lock must be on the third notch from the top - Move the lock up to obtain a leaner mixture - Move the lock down to obtain a richer mixture. Thus, carburetion can be adapted to different weather conditions - Replace the tapered pin if it shows signs of wear...
  • Page 85 SMT RCR Engine - If the throttle valve is replaced, fit another one with the standard settings indicated on the upper part as shown in the photograph - Refit the complete the carburettor - Refit the carburettor to the engine, connect the fuel pipes again, the mixer oil intake pipes and the low-pressure pipe for the fuel cock control Adjusting the idle...
  • Page 86 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 87 SMT RCR Suspensions Front Front suspension removal - Remove the stem and the fork leg from the fork plate. - Secure the stem adequately in the vice with alu- minium clamps to avoid scratching the stem. - Loosen the upper screw. - Remove the stem upper lock together with the preloading bushing.
  • Page 88 SMT RCR Suspensions - Remove the dust guard with the aid of a screw- driver. - Remove the lower screw located on the fork leg in order to release the stem from the fork leg. - Remove the stem from the fork leg. - Remove the aluminium bushing that guides the stem into the fork leg.
  • Page 89 SMT RCR Suspensions - Take out the hydraulic cartridge from the stem upper part. - Lock the fork leg in the vice being careful to use two aluminium clamps to avoid scratching the fork leg. - Place a protection cloth on the fork leg edge and remove the oil seal as indicated in the photograph.
  • Page 90 SMT RCR Suspensions - Prepare a support with two gauging blocks in X. - Position the stem as shown in the photograph and use a dial gauge check alignment. Serviceability limit: 0.2 mm - Check the fork spring length. - Make sure the spring does not show any signs of abnormal wear or distortions.
  • Page 91 SMT RCR Suspensions Name Torque in Nm Fork plate lower clamp 8 ÷ 10 Nm Front wheel shaft 70-80 Front brake calliper clamps 17 ÷ 19 Nm * Rear - The rear shock absorber unit does not require maintenance. Replace it if there are any signs of malfunctioning.
  • Page 92 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 93 SMT RCR Braking system Rear brake calliper Rear brake calliper replacement - Support the scooter rear carriage axle adequate- ly so that the rear wheel does not touch the ground. - Detach the oil brake hose from the calliper, pour- ing the fluid inside a container.
  • Page 94 SMT RCR Braking system Front brake disc Brake disc replacement - Remove the front wheel operating on the axle locking screw and on the wheel axle nut as shown in the photograph. - Undo the six disc retainer. - Upon refitting, position the disc correctly making sure that it rotates in the right direction.

  • Page 95: Front Brake Pads

    SMT RCR Braking system Front brake pads - To facilitate this operation, remove the two brake calliper clamps shown in the figure. - With the calliper removed from the support but still connected to the oil pipe, remove the two pad locks.

  • Page 96: Rear Brake Pads

    SMT RCR Braking system - Upon refitting, operate in reverse order bearing in mind that the arrow on the plate indicates the disc sense of rotation. Rear brake pads Brake pad replacement - Support the scooter rear carriage axle adequate- ly so that the rear wheel does not touch the ground.
  • Page 97 SMT RCR Braking system - Pads must be replaced if the friction material thickness is less than 1.5 mm. - Upon refitting, operate in reverse order bearing in mind that the arrow on the plate indicates the disc sense of rotation. Fill Rear - combined Oil refill and purging...
  • Page 98 SMT RCR Braking system CAUTION WHILE CARRYING OUT THESE OPERATIONS, THE SCOOTER MUST BE UPRIGHT. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SUR- ROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED.
  • Page 99 SMT RCR Braking system - Undo the bleed screw. - Apply the tube of the special tool to the bleed screws. Upon purging, it is necessary to refill the oil reservoir permanently while working with a Mi- tyvac pump on the bleed screw until no more air comes out of the system.
  • Page 100 SMT RCR Braking system Specific tooling 020329Y MityVac vacuum-operated pump Front brake pump - Operate on the two U bolt clamps (see figure). - Disconnect the pipe and collect the brake oil in a container. - Upon refitting, perform the operation but in re- verse order.
  • Page 101 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 102: Coolant Replacement

    SMT RCR Cooling system Coolant replacement - Connect the sleeve to the hydraulic pump and the radiator - Lift the reservoir cover, remove the cap and refill the reservoir with the recommended coolant - Loosen the bleed screw on the pump cover and then tighten the screw again - Start the engine and take it to normal running temperature.
  • Page 103 SMT RCR Cooling system - Detach the gasket (1) - Undo the rotor screw (2) - Unscrew the hydraulic pump rotor (3) - Drain out all the oil from the engine - Remove the crankcase right cover - Remove the hydraulic pump shaft (1) and the transmission pinion (2) - As soon as there is the slightest indication of coolant or oil leaking from the breather, replace the...
  • Page 104 SMT RCR Cooling system - Fit the hydraulic pump shaft and the transmission pinion - Insert the washer (3) - Fit the crankcase cover - Fit the pump rotor (1) and its screw Locking torques (N*m) Pump rotor: 2 Nm - Insert the gasket on the pump cover, the cover and the two sleeves - Pour recommended oil in the transmission - Fill up the cooling system...
  • Page 105 SMT RCR Cooling system Characteristic Activation 124 ± 3°C Deactivation 114 ± 3°C Thermostat check Measuring the valve opening temperature: - Immerse the thermostat and the thermometer in hot water. Neither of them should get into contact with the container walls or bottom; otherwise, the reading will not be accurate.
  • Page 106 INDEX OF TOPICS CHAS HASSIS...
  • Page 107 SMT RCR Chassis Seat - Lift the fuel tank cap lid - Remove the saddle by operating on the two clamps indicated in the photograph Headlight assy. Headlamp front cowl replacement - Remove the rubber connections from the slots as indicated in the figure - Remove the headlamp retaining bracket from the front cowl by gently pressing the bracket as indi-...
  • Page 108 SMT RCR Chassis - Remove the headlamp central fixing/adjustment screw - Remove the screws fixing the turn indicators sup- port bracket from the front cowl Front headlight replacement - After removing the headlamp front cowl and in order to remove the headlight, operate on the tabs indicated in the photograph and on the headlamp fixing/adjustment screws CHAS - 108...
  • Page 109 SMT RCR Chassis Footrest Passenger footrest removal - Remove the screw shown in the figure and the passenger footrests Side fairings Rear fairings - Remove the saddle - Remove the two fixing screws indicated in the photograph - Remove the screw shown in the figure and loca- ted under the side fairing Air deflector - Undo the two screws indicated in the photograph...
  • Page 110 SMT RCR Chassis Front fairing replacement - To replace the fairing halves, remove the fixing screws indicated in the figure Rear mudguard - Remove the rear mudguard by loosening the 4 screws indicated in the figure CHAS - 110...

  • Page 111: Fuel Tank

    SMT RCR Chassis Fuel tank - Remove the saddle - Remove the front fairing halves - Remove the mixer oil reservoir - Remove the metal clamp fixing the reservoir by operating on the two screws indicated in the pho- tograph - Remove the electrical cable harness of the low fuel sensor - Remove the fuel pipe and the low-fuel intake pipe...
  • Page 112 SMT RCR Chassis Radiator fitting - Fit the radiator following the removal procedures but in reverse order - Fill the reservoir with the recommended coolant and make sure there are no leaks in the system Locking torques (N*m) Radiator clamps: 8 ÷ 10 Nm Expansion tank - Remove the side Fairings - Drain out the expansion tank...
  • Page 113 SMT RCR Chassis CHAS - 113...
  • Page 114 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 115 SMT RCR Pre-delivery Aesthetic inspection Vehicle check - Paintwork - Plastic parts fitting - Damage - Dirt Tightening torques inspection Locking Check - All the tightening torques - External screw of covers Electrical system Electrical system - Fill up the battery with acid for batteries, charge it using a suitable battery charger. - Key switch - Low-beam light, high-beam light, warning lights, tail light - Headlight adjustment...

  • Page 116: Road Test

    SMT RCR Pre-delivery 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. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES;...
  • Page 117 SMT RCR Pre-delivery Be very careful when handling fuel. Functional inspection Functional check - Brake lever travel - Throttle control adjustment and free travel - Uniform turning of the steering PRE DE - 117...
  • Page 118 Air filter: 24 Battery: 33, 39, 44, 45, 47, 112 Brake: 93–96, 100 Carburettor: 21, 80, 82 Coolant: 102 Fuel: 32, 79, 111 Fuses: 44 Headlight: 28, 107 Identification: 7 Maintenance: 19 Spark plug: 23 Tank: 111, 112 Transmission: 32 Tyres: 10...

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