Derbi GP1 250 c.c. Manuals

Manuals and User Guides for Derbi GP1 250 c.c.. We have 1 Derbi GP1 250 c.c. manual available for free PDF download: Workshop Manual

Derbi GP1 250 c.c. Workshop Manual (247 pages)

GP1 125-250 c.c.

Brand: Derbi | Category: Scooter | Size: 12.91 MB

Contents
4
General Information
9
Safety/Maintenance Regulations
9
General Technical Data
10
Dimensions and Weight
10
Engine Specifications
10
Transmission Specifications
11
Capacities
11
Electrical Components Specifications
12
Frame and Suspensions Specifications
12
Brakes Specifications
12
Secondary Air
13
Wheel and Tyres Specifications
13
Carburetor HEININ 125/WALBRO Specifications
16
Carburetor HEININ 250 Specifications
17
Carburetor WALBRO 250 Specifications
18
Chassis Tightening Torques
19
Exhaust Pipe
20
Engine Lubrication
20
Cylinder Head
20
Transmission
21
Flywheel
21
Engine Crankcase and Shaft
22
Cooling
22
Overhaul Data
23
Assembly Clearances
23
Cylinder-Piston Assy
23
Categories Coupling 125
23
Coupling Categories Engine 250
24
Piston Rings
24
Uprating Table Engine 125
24
Oversizes Engine 250
25
Crankcase - Driving Shaft - Bench Half Bearing
25
Fitting Clearance
26
Crancshaft - Crankcase Axial Clearance/Carter
26
Slot Packing System
27
125CC Version with Fibre Head Gasket
27
125CC Version with Metallic Head Gasket
28
Shimming 250
29
Oversizes Engine
30
Recomendeds Products
30
Recommended Tools
31
Preparation for Removal and Dismantling
31
Replacement Parts
32
Seals, Retaining Rings and O Rings
32
Tab/Spacer Washers and Split Pins
32
Bearings and Retaining Rings
32
Locking Rings
33
Special Tools
33
Maintenance Chart
41
Every 3000 KM
41
Every 2 Years
41
At 1000/6000 KM or 4/12 Months
41
At 12000 KM or 24 Months and 60000 KM
42
At 18000 KM and 54000 KM
43
At 24000 KM and 48000 KM
43
At 30000 KM, 42000 KM and 66000 KM
44
At 36000 KM
44
At 72000 KM
45
Periodic Maintenance
47
Carburettor
48
Checking the Spark Advance
49
Version 125/250
49
Spark Advance Variation (Version 125)
51
Spark Advance Variation (Version 250)
52
Spark Plug
53
Hub Oil
54
Air Filter
55
Hub Oil Check/Replacement
55
Air Filter Cleaning
56
Engine Oil Replacement/Check
57
Engine Oil Filter
58
Oil Pressure Warning Light
59
Checking the Ignition Timing
59
Checking the Valve Clearance
60
Cooling System
60
Braking System
61
Headlight Adjustment
62
SAS Filters Inspection and Cleaning
62
Engine 125
63
Dismantling
65
Seat Side Trim
65
Cowling
65
Lower Cowling Cover
66
Water-Oil Tank Cover
66
Side Covers
66
Shield Inner Cover
67
Battery Cover
67
Petrol Tank Cover
67
Helmet Carrier
68
Footrests
69
Shield
69
Engine
70
Exhaust Assy Removal
70
Removal of the Engine from the Vehicle
70
Automatic Transmission Cover
72
Air Duct
72
Removing/Refitting the Driven Pulley Shaft Bearing
73
Baffle/Plastic Roller
74
Removing the Driven Pulley
74
Inspecting the Clutch Drum
74
Removing the Clutch
75
Inspecting the Clutch
77
Pin Retaining Collar
77
Removing the Driven Half - Pulley Bearing
78
Inspecting the Driven Fixed Half - Pulley
78
Inspecting the Driven Sliding Half Pulley
79
Refitting the Driven Half - Pulley Bearing
80
Mobile Line Half Pulley Dimensions
80
Refitting the Driven Pulley
81
Inspecting the Clutch Spring
82
Refitting the Clutch
83
Drive Belt
86
Inspecting the Roller Case
88
Refitting the Driving Pulley
89
Refitting the Transmission Cover
90
End Gear
91
Removing the Hub Cover
91
Removing the Wheel Axle
91
Removing the Hub/Wheel Axle Bearings
92
Removing the Driven Pulley Shaft Bearing
93
Inspecting the Hub Shaft/Cover
93
Refitting the Wheel Axle/Hub Cover Bearings
94
Refitting the Hub Bearings/Cover
96
Flywheel Cover
96
Removing the Stator
97
Refitting the Stator
98
Refitting the Flywheel Cover
98
Flywheel and Starting
99
Removing the Starter Motor
99
Removing the Flywheel Magneto
100
Inspecting the Flywheel Components
102
Refitting the Flywheel Magneto
102
Refitting the Starter Motor
103
Cylinder Assy and Timing System
104
Removing the Rocker-Arms Cover
104
Removing the Timing System Drive
104
Removing the Cam Shaft
106
Removing the Cylinder Head
106
Removing the Valves
107
Removing the Cylinder - Piston Assy
107
Inspecting the Small End
108
Inspecting the Wrist Pin
108
Inspecting the Piston
108
Inspecting the Cylinder
111
Inspecting the Piston Rings
112
Version 125/250 Seal Rings
112
Removing the Piston
113
Choosing the Gasket
114
Compression Ratio Version 250
116
Refitting the Piston Rings
117
Refitting the Cylinder
117
Inspecting the Cylinder Head
118
Inspecting the Timing System Components
118
Inspecting the Valve Sealings/Housings
119
Inspecting the Valves
120
Inspecting the Springs and Half-Cones
121
Refitting the Valves
121
Inspecting the Cam Shaft
122
Refitting the Timing System Components
123
Refitting the Rocker-Arms Cover
129
Refitting the Intake Manifold
129
Crankcase - Crankshaft
130
Splitting the Crankcase Halves
130
Inspecting the Crankshaft Alignment
134
Inspecting the Crankcase Halves
135
Inspecting the Crankshaft Plain Bearings
136
Refitting the Crankcase Halves
138
Lubrication Conceptual Diagrams
140
Lubrication Circuit
140
Oil Pressure Check
141
Crankshaft Oil Seals
141
Refitting
142
Oil Pump Removal
144
Oil Pump Inspection
145
Oil Pump Refitting
146
Removing the Oil Sump
146
Inspecting the By-Pass Valve
147
Refitting the Oil Sump
147
SAS Valve
148
Inspecting the Cut-Off
149
Fuel Supply
150
Removing the Carburettor
150
Refitting the Carburettor
160
Level Check
165
Inspecting the Valve and Needle
167
Inspecting the Automatic Choke Device
170
Forks, Shock Absorber, Engine Support and Stand
173
Dismantling Front Suspension
174
Inspecting the Front Forks
176
Inspection
180
Swing-Arm Removal
181
Checking the Swinging Arm
182
Exhaust Bracket Removal
182
Exhaust Bracket Overhaul/Refitting
183
Centre Stand Removal/Reassembly
184
Front Wheel and Brake
185
Rear Wheel 125CC
185
Rear Wheel 250CC
186
Dismantling/Inspecting the Front Wheel
187
Dismantling the Front Disk Calliper
189
Assembling the Front Wheel
195
Rear Wheel and Brakes
197
Rear Wheel Dismantling
199
Dismantling the Rear Disk Calliper
199
Inspecting/Fitting the Rear Wheel
206
Circuit Diagram Engine 250
207
Engine Cooling Circuit
207
Circuit Diagram Engine 125
208
Water Pump - Overhaul
209
Electrical System GP1 125-250
219
Checking Connectors
220
Inspection Steps
221
Digital Instruments Unit
221
Ignition
222
Lights and Automatic Choke
223
Recharging the Battery and Starting
224
Sensors and Indicators
225
Turn Indicators and Horn
226
Ignition Circuit
227
Stator Check
229
Voltage Regulator Check
229
Recharge System Voltage Check
230
Choke Inspection
230
Fuses
231
Dismantling the Battery
231
Battery - Initial Charge
233
Capacity
233
Inspecting the Charging Conditions
234
Recharging
235
Charging System
236
Standard Battery Charging Time
236
Standard Values to Determine the State of the Battery
236
Monitoring Graph to Determine Battery Condition
236
Troubleshooting
237
Engine Poor Performance
237
Rear Wheel Turning with Idle Engine
238
Starting Difficulties
238
Excessive Oil Consumption/Smoke Upon Exhaust
239
Insufficient Lubrication Pressure
239
Engine Tends to Cut-Off at Full Throttle/Idle
240
High Fuel Consumption
241
Excessive Exhaust Noise
241
SAS Malfunctions
242
Transmission and Brakes
242
Insufficient Braking
242
Braking Vibrations or Noise
243
Electrical System
243
Brakes Overheating
243
Turn Signal Lights Malfunction
244
Heavy Steering
244
Noisy Suspension
245
Suspension Oil Leakage
245

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Derbi GP1 250 c.c. Manuals

Derbi GP1 250 c.c. Workshop Manual (247 pages)

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