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Derbi Dirtboy 10 Workshop Manual

Minimoto 50 c.c. 4t.
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ORKSHOP MANUAL
MINIMOTO 50 C.C. 4T

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Table of Contents

   Summary of Contents for Derbi Dirtboy 10

  • Page 1 ORKSHOP MANUAL MINIMOTO 50 C.C. 4T...
  • Page 2 The intention is to provide as much assistance as possible to mechanics working in our brand’s dealers and sub-dealers. Due to its constant commitment to improving its products, DERBI - NACIONAL MOTOR, S.A.U. reserves the right to introduce any modifications it deems fit, without prior warning.
  • Page 3: Table Of Contents

    INDEX I N D EX I N D EX ND E X GENERAL INFORMATION Pág. 4 CARACTERISTICS Pág. 5-6 TIGHTENING TORQUES Pág. 7 M AINTENANCE Pág. 10 MAINETANCE CHART Pág. 10-11 ENGINE OIL Pág. 11 DISTRIBUTION Pág. 13 DISTRIBUTION - COMPRESSION MOTOR Pág.
  • Page 4: General Information

    GENERAL INFORMATION G E N ER AL IN F O R M AT I O N ULES ULES This section describes the general safety rules and service recommendations to be observed. AFETY RULES AFETY RULES - Should it be necessary to run the engine in order to perform certain operations, please ensure the area is adequately ventilated and, if required, use appropriate fume extractors;...
  • Page 5: Caracteristics

    CHARACTERISTICS C H A R AC T ER I S TI C S CHASSIS CODE ENGINE CODE DIRTBOY 10 ZEMMR4CC24 ¿AXXXXXX? C391M ¿XXXX? DIRTKID 12 ZEMMS4CC64 ¿AXXXXXX? C391M ¿XXXX? ARACTERISTICS ARACTERISTICS CHASSIS, Frame Steel WHEELS AND Fork Steel BRAKES Inner tube 2,5 x 10”...
  • Page 6 CHARACTERISTICS C H AR AC T ER I S TI C S ECHNICAL DATA ECHNICAL DATA SPECIFICATION DESC. / QUANTITY Engine Four-stroke mono-cyl-inder Bore per stroke 39 x 41,8 mm. Displacement 49,93 mm. Compression ratio 11,5 ÷12,5:1 Carburettor Dell’orto PHVA Recommended spark plug Champion RG 4 HC overhead single camshaft, two valves, chain controlled on l.h.
  • Page 7: Tightening Torques

    TIGHTENING TORQUES T I G H T E N IN G TO R QU E S NGINE ASSEMBLY NGINE ASSEMBLY TORQUE IN Nm NAME Spark plug: 10 ÷ 15 Nm Head cover screw 8 ÷ 10 Nm 6 ÷ 7 + 135º+90º Nm for first fitting, Head-cylinder stud nut 6 ÷...
  • Page 8: M Aintenance Mainetance Chart Pág

    MAINTENANCE M AI N T ENA N C E AINTENANCE CHART AINTENANCE CHART FREQUENCY ACTION Engine Oil - Level Check/Top up Every 3 month Spark plug/electrode gap - Check Every 3 month Every 3 month Air Filter - Cleaning Every 3 month Idle speed / Fuel - Adjust Every 6 month Acceleration command - Adjustment...
  • Page 9 MAINTENANCE M A I N T E NA N C E AINTENANCE CHART AINTENANCE CHART ACTION FREQUENCY At 80 hours or 24 month Engine oil - Replacement Idle speed / Fuel - Change At 80 hours or 24 month Filtro aceite - Sustitución At 80 hours or 24 month Valve clearance - Check At 80 hours or 24 month...
  • Page 10: Engine Oil

    MAINTENANCE M A I N T E N AN C E LECTRICAL CHARACTERISTICS Distance between electrodes 0.8 ÷ 0.9 mm AGNETIC FLYWHEEL RESISTANCE AGNETIC FLYWHEEL RESISTANCE EARTH YELLOW Infinite 55 ± 10% EARTH Infinite BROWN EARTH BLACK 100 ± 10% EARTH 100 ±...
  • Page 11 MAINTENANCE M A I N T E NA N CE Fill up the engine with the recommended oil, using the filler hole on the RHS engine cover. Tighten the cap manually. N.B. LET THE ENGINE RUN FOR A FEW MINUTES, THEN CHECK THE OIL LEVEL AGAIN, WITH THE ENGINE COLD;...
  • Page 12 MAINTENANCE MA I N T E N AN C E Ensure the reference mark on the camshaft control ring is aligned with that machined on the head, as shown in the second figure. If the marking is on the side opposite to the reference on the head, perform a complete revolution of the crankshaft, since the piston must be at the TDC of the ignition phase.
  • Page 13 MAINTENANCE M AI N T E NA N C E HECKING THE END COMPRESSION PRESSURE SS O - With the engine cold, remove the spark plug cap. - Remove the spark plug. - Using a 10mm adapter, install a compression test manometer on the spark plug housing, and tighten at the prescribed torque.
  • Page 14 ENGINE E N G I N E UTOMATIC TRANSMISSION RANSMISSION COVER - Remove the seven cover fixing screws. - Remove the screw and the kick-start. - Remove the seeger ring and the washer shown in the figure. - Remove the sector gear. ICKSTART ICKSTART - Search for excessive wear in the toothed segment, the toothed...
  • Page 15 ENGINE E N G I N E - Check the thickness of the friction material of the masses. If the friction material of the mass is found to be missing the circumferential grooves or cleats, the clutch is to be considered excessively worn and the masses should therefore be replaced.
  • Page 16: End Gear Shaft

    ENGINE E N G I N E EFITTING THE CLUTCH EFITTING THE CLUTCH - Before refitting the assembly, carefully grease the roller bearing inside the gear housing. - Refit the clutch assembly, the drum washer, and the nut using the special tool. -After refitting, ensure the drum spins freely.
  • Page 17 ENGINE E N G I N E EMOVING THE STATOR EMOVING THE STATOR - Remove the two stator fixing screws as shown in the figure. EFITTING THE FLYWHEEL COVER EFITTING THE FLYWHEEL COVER According to the versions (kick-start/electric). Locking torques (N*m) Flywheel cover fixing screw: 2,5 - 3 Nm LYWHEEL AND STARTING - Restrain the rotation of the flywheel using the special tool.
  • Page 18: Removing Therocker - Arms Cover

    ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E NG I N E - CY LINDE R AS SY. A N D T IMIN G SYST E M EMOVING THE ROCKER EMOVING THE ROCKER ARMS COVER ARMS COVER Remove the four tappet cover fastenings; remove the cover complete with the 0-ring.
  • Page 19: Cam Shaft

    ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R A SS Y. A N D TI MIN G SYST EM - Remove the tappet cover. - Remove the central screw and the belleville washer shown in the figure using the specific tool to lock camshaft ring gear.
  • Page 20 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R A SS Y. AN D T IMIN G S YST E M Specific tooling 020450Y Camshaft fitting/removing tool 004499Y Bearing extractor Remove the rocker arm pivot through the hole on the flywhe- el side and simultaneously remove the rocker arms.
  • Page 21 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R A SS Y. A N D TI MIN G SYST EM EMOVING THE VALVES EMOVING THE VALVES Using the specific tool with the part shown in the figure, re- move the cotter halves, the caps and the springs from both valves.
  • Page 22 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM EN G I N E - CY LINDE R A SS Y. AN D T IMIN G S YST E M NSPECTING THE SMALL END Using an inside micrometer, measure the small end diame- ter.
  • Page 23 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R AS SY. A ND TIMIN G SYSTE M - Measure the piston outside diameter perpendicularly to the piston pin axis. - Take the measurement 27 mm from the piston top as shown in the figure.
  • Page 24 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM EN G I N E - CY LINDE R A SS Y. AN D T IMIN G S YST E M - Measure the piston protrusion compared to the head plane and use the chart below, to determine the proper base gas- ket thickness.
  • Page 25 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R AS SY. A ND TIMIN G SYSTE M TANDARD MATING PLAY NAME DIMENSIONS INITIALS QUANTITY 0,030 ÷ 0,065 mm 1º Ring 0,020 ÷ 0,055 mm 2º...
  • Page 26 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E NG I N E - CYLI ND ER A S SY. A N D T IMIN G SYST E M N.B. BEFORE REPLACING THE PISTON RINGS ONLY, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED.
  • Page 27 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LIND ER A SS Y. A N D T IMING SYST EM EMOVING THE PISTON EMOVING THE PISTON - Fit the piston and the piston pin to the connecting rod. The arrow on the piston must face the exhaust side.
  • Page 28 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R A SS Y. A N D T IMING SYST EM EFITTING THE PISTON RINGS EFITTING THE PISTON RINGS - Fit the scraper starting with the spring. Ensure that the scra- per ends do not overlap.
  • Page 29: Inspecting The Cylinder Head

    ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LI NDER ASS Y. AN D T IMIN G SYS TE M N.B. SEE “REFITTING THE TIMING CHAIN”, TO BE CARRIED OUT BEFORE RECOUPLING THE HALFCRANKCASES. - Insert the spacer on the camshaft.
  • Page 30 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LIND ER A SS Y. A N D T IMI NG SYST EM TANDARD DIAMETER SPECIFICATIONS DESC. / QUANTITY Ø 32,015 ÷ 32,025 mm Standrad diameter A: Ø...
  • Page 31 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E NG I N E - CY LI NDER A S SY. A N D TIMIN G SYSTE M NSPECTING THE VALVE SEALINGS NSPECTING THE VALVE SEALINGS Measure the width of the sealing surface on the valve seats. HARACTERISTIC Sealing surface width Intake: 1,5 mm...
  • Page 32 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LI NDER ASS Y. AN D T IMIN G SYS TE M NSPECTING THE VALVES NSPECTING THE VALVES - Insert the valves into the cylinder head. - Alternately test the intake and exhaust valves.
  • Page 33 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E NG I N E - CY LI ND ER ASS Y. A N D T IMI NG SYST EM HARACTERISTIC Minimum allowable diameter - Intake: 4,970 mm Minimum allowable diameter - Exhaust: 4,960 mm Standard clearance - Intake: 0,015 ÷...
  • Page 34: Inspecting The Cam Shaft

    ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CYLIND ER AS SY. A N D TI MIN G SYST EM NSPECTING THE CAM SHAFT NSPECTING THE CAM SHAFT - Ensure that the camshaft bearings are not abnormally worn.
  • Page 35 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM EN G I N E - CYLIND ER A S SY. A N D T IMIN G SYST E M - Replace any damaged parts. HARACTERISTIC Minimum allowable diameter «A»: Ø 10,970mm Minimum allowable diameter «B»: Ø...
  • Page 36: Refitting The Timing Chain

    ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R AS SY. A N D T IMIN G SYST E M - Tighten the pivot and camshaft check screw complete with the washer shown in the figure. Locking torques (N*m) Rocker-arm shaft and camshaft bearing screw: 3 - 4 Nm - To complete the fastening of the cylinder head, tighten the...
  • Page 37 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CYLIND ER AS SY. A N D TI MIN G SYST EM - Fit the pulley on the camshaft. - Fit the belleville washer so that its outer rim is in contact with the pulley.
  • Page 38 ENGINE - CYLINDER ASSY. AND TIMING SYSTEM E N G I N E - CY LINDE R AS SY. A ND TIMIN G SYS TE M NSPECTING THE RADIAL AIR GAP Inspecting the kick-starter: - Using a thickness gauge, measure the two metallic protru- sions.
  • Page 39 ENGINE - CRANKCASE - CRANKSHAFT EN G I N E - CR ANKCAS E - CRA NK SHAFT PLITTING THE CRANKASE HALVES PLITTING THE CRANKASE HALVES - Remove the following assemblies: Transmission cover, clutch, gears, as described in the related paragraphs: «Re- moving the transmission cover», «Removing the clutch», and «Removing the gear-shafts.
  • Page 40 ENGINE - CRANKCASE - CRANKSHAFT E N G I N E - CR ANKCAS E - CRA N KSH AFT - Rest the flywheel-side crankcase-half on a flat surface, adequately supported and with the crankshaft vertical. - Insert the timing chain positioning it at the edge of its housing so that in won’t interfere with the refitting of the crankshaft assembly, the bearing, and the timing gear- shaft.
  • Page 41: Refitting Crankshaft Pág

    ENGINE - CRANKCASE - CRANKSHAFT E N G I N E - CR ANKCASE - CRAN KS HAFT EFITTING THE CRANKSHAFT EFITTING THE CRANKSHAFT - Check the connecting rod axial play. - While holding the crankshaft manually, check the connec- ting rod radial play.
  • Page 42: Refitting The Crankase Halves

    ENGINE - CRANKCASE E N G I N E - CR ANKCAS E EFITTING THE CRANKCASE HALVES EFITTING THE CRANKCASE HALVES - Using a heat gun, heat the bearing housing on the transmission-side crankcase-half up to approximately 120 °C. Install the bearing and the oil conveying plate with its gasket, tightening the three screws at the prescribed torque, as shown in the figure.
  • Page 43 ENGINE - CRANKCASE E NG I N E - CRA NKCA S E - Lubrificare con olio motore Ie rispettive sedi come indicate in figura. Montare la guarnizione utilizzando come riferimento i due grani. - Accostare i due carter e montare Ie 10 viti e bloccare alia coppia prescritta.
  • Page 44: Oil Pump

    ENGINE - OIL PUMP E N GI N E - O IL P UMP UBRICATION UBRICATION CRANKSHAFT OIL SEALS Removal - Extract the flywheel-side oil seal from the crank- case taking care not to damage or score the crankcase. - Pour engine oil over the oil seal and its seat in the crankcase.
  • Page 45 ENGINE - OIL PUMP E NG I N E - OI L P UM P Measure the distance between the outer rotor and the pump body (see figure). HARACTERISTIC Maximum allowable clearance: 0,20 mm Check the axial play of the rotors using a trued bar as shown in the figure.
  • Page 46: Carburettor

    ENGINE - CARBURETTOR E N G I N E - CAR BURETTOR UEL SUPPLY UEL SUPPLY REMOVING THE CARBURETTOR - In order to detach the carburettor from the engine, loosen the intake manifold and reed-valve pipe clamp screw. - To carry out further operations on the carburettor, discon- nect the throttle cable and the fuel supply tube.
  • Page 47 ENGINE - CARBURETTOR E NG I N E - CAR BUR ETTOR - Should anomalies be observed for these components, pro- ceed with the replacement. - Refit the throttle valve cover. - Refit the main and idling jets. - Refit the float and its conical needle. - Refit the float bowl ensuring the seal is properly positioned in its housing.

This manual is also suitable for:

Dirtkid 12

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