Derbi GP1 50 cc Manuals

Manuals and User Guides for Derbi GP1 50 cc. We have 1 Derbi GP1 50 cc manual available for free PDF download: Workshop Manual

Derbi GP1 50 cc Workshop Manual (139 pages)

Brand: Derbi | Category: Motorcycle | Size: 5.96 MB

Introduction
2
Contents
4
General Information
9
Safety Regulations
9
Maintenance Regulations
9
General Technical Data
10
Dimensions and Weight
10
Engine
10
Transmission
11
Capacity
11
Electrical System
11
Frame and Suspensions
12
Braking System
12
Wheels and Tyres
12
Carburettor
12
Chassis Tightening Torques
14
Engine Tightening Torques
15
Connection Piston and Cylinder
16
Piston Rings
16
End Play between Crankcase, Crankshaft and Connecting Rod
17
Slot Packing System
17
Recommended Tools
19
Preparation for Removal and Dismantling
19
Replacement Parts
20
Seals, Retaining Rings and O-Rings
20
Tab/Spacer Washers and Split Pins
20
Bearings and Retaining Rings
20
Locking Rings
21
Special Tools
21
Periodic Maintenance
25
Maintenance Chart
25
Spark Plug
30
Hub Oil
31
Check
31
Replacement
31
Characteristic
31
Air Filter
32
Checking the Ignition Timing
33
Headlight Adjustment
35
Dismantling
36
Seat Side Trim
36
Cowling
36
Lower Cowling Cover
37
Water-Oil Cover
37
Side Covers
37
Shield Inner Cover
38
Petrol Tank Cover
38
Helmet Carrier
39
Footrests
40
Shield
40
Direct Access to the Bottom of the Carburettor
41
Dismantling Footrests/Extracting Complete Filter Box
41
Disconnect the Secondary Air Pipe
41
Extract Carburettor Air Inlet Pipe
41
Extract Carburettor
42
Dismantling the Machine's Engine
44
Automatic Transmission
44
Removing the Driven Pulley Shaft Bearing
45
Refitting the Driven Pulley Shaft Bearing
45
Removing the Driven Pulley
46
Inspecting the Clutch Drum
46
Removing the Clutch
46
Inspecting the Clutch
47
Pin Retaining Collar
47
Removing the Driven Half-Pulley Bearing
48
Inspecting the Driven Fixed Half Pulley
48
Inspecting the Driven Sliding Half Pulley
49
Refitting the Driven Half-Pulley Bearing
50
Inspecting the Clutch Spring
50
Refitting the Clutch
50
Refitting the Driven Pulley
51
Drive Belt
51
Removing the Driving Pulley
52
Mixer Gears and Belt
52
Inspecting the Rollers Case
52
Refitting the Driving Pulley
53
Dismantling Engine Pinion
54
Removing the Hub Cover
54
Dismantling Output Pinion Shaft Bearing
55
Inspecting the Hub Shaft
56
Inspecting the Hub Cover
56
Refitting the Wheel Axle Bearing
57
Refitting the UB Cover
58
Flywheel Cover
58
Removing the Stator
58
Refitting the Stator
58
Refitting the Flywheel Cover
59
Flywheel and Starting
59
Removing the Starter Motor
59
Removing the Flywheel Magneto
59
Inspecting the Flywheel Components
60
Refitting the Flywheel Magneto
60
Refitting the Starter Motor
61
Cylinder Assy. and Timing System
61
Removing the Intake Manifold
61
Removing the Cylinder Head
61
Removing the Cylinder-Piston Assy
62
Inspecting the Small End
62
Inspecting the Wrist Pin
62
Inspecting the Piston
63
Inspecting the Cylinder
63
Inspecting the Piston Rings
64
Removing the Piston
64
Inspecting the Timing System Components
65
Crankcase - Crankshaft
66
Splitting the Crankcase Halves
66
Removing the Crankshaft Bearings
66
Refitting the Crankshaft Bearings
67
Inspecting the Crankshaft Alignment
68
Refitting the Crankshaft
68
Refitting the Crankcase Halves
69
Lubrication
70
Crankshaft Oil Seals
70
Oil Pump
71
Removal
71
Refitting
71
Fuel Supply
72
Forks
73
Sebac Forks
73
Marzocchi Forks
74
Dismantling Front Suspension
75
Inspecting the Front Forks
77
Shock Absorber and Swinging Arm
79
Front Wheel and Brake
81
Front Wheel Diagram
81
Inspecting the Front Wheel
82
Dismantling the Front Disk Calliper
84
Fitting the Front Calliper
84
Extracting the Front Brake Pads
85
Fitting the Front Brake Pads
85
Inspecting the Pads for Wear
85
Extracting the Front Brake Cylinder
85
Fitting the Front Master Cylinder
86
Checking the Brake Calliper Main Cylinder
87
Extracting the Brake Disk
87
Fitting the Brake Disk
87
Wear to the Brake Disk
87
Brake Disk Distortion
88
Disk Deviation from Centre
88
Bleeding the Brake System Pipe
88
Fit
89
Assembling the Front Wheel
90
Wheel Diagram
92
Dismantling the Rear Disk Calliper
93
Fitting the Rear Calliper
94
Extracting the Rear Brake Pads
94
Fitting the Rear Brake Pads
94
Rear Wheel and Brakes
95
Extracting the Rear Main Cylinder
95
Fitting the Rear Main Cylinder
95
Checking the Rear Main Cylinder (Visual Check)
96
Checking the Rear Calliper Main Cylinder
96
Brake Disk Wear
97
Inspecting the Rear Wheel
100
Fitting the Rear Wheel
100
Transmision Chain
100
Inspecting the Drive Chain
102
Chain Sprocket
102
Fitting the Chain Sprocket and the Drive Chain
103
Cooling System
104
System Bleed
104
Water Pump-Overhaul
104
Thermostat
107
GP1 50 C.C. Wiring Diagram
109
Switzerland
110
Checking Connectors
111
Inspection Steps
112
Digital Instruments Unit
112
Ignition
113
Automatic Choke and Lights
114
Battery Recharge and Starting
115
Level Indicators
116
Turn Indicators and Horn
117
Checks and Inspections
118
Checking the Pick up
118
Checking the Recharge Coil
118
Ignition Circuit
119
Stator Check
119
Voltage Regulator Check
119
Interventions
120
Fuses
123
Dismantling the Battery
123
Filling with Electrolyte
123
Battery-Initial Charge
125
Interchangeability
126
Inspecting the Charging Conditions
126
Recharging
127
Charging System
128
Standard Values to Determine the State of the Battery
128
Standard Battery Charging Time
128
Monitoring Graph to Determine Battery Condition
128
Troubleshooting
129
Poor Performance
129
Rear Wheel Spins at Idle
130
Starting Difficulty
130
Excessive Oil Consumption/Exhaust Smoke
131
Engine Tends to Cut-Off at Full Throttle/At Idle
131
Engine Stops at Full Throttle/At Idle
131
High Fuel Consumption
132
Excessive Consumption/Exhaust Noise
132
Noise Increase
132
Engine Overheating
132
SAS Malfunctions
133
Looseness of Rubber Union of Secondary Air Tube to Silencer
133
Transmission and Brakes - Clutch Grabbing or Performing Inadequately
133
Insufficient Braking
134
Braking System Failure
134
Brakes Overheating
134
Battery
135
Steering and Suspensions - Rear Wheel
135
Poor Road Handling
135
Electrical System
135
Heavy Steering
136
Excessive Steering Play
136
Noisy Suspension
136
Suspension Oil Leakage
137

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Derbi GP1 50 cc Workshop Manual (139 pages)

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