Derbi GPR 125 Racing Manuals

Manuals and User Guides for Derbi GPR 125 Racing. We have 2 Derbi GPR 125 Racing manuals available for free PDF download: Workshop Manual

Derbi GPR 125 Racing Workshop Manual (248 pages)

4-stroke

Brand: Derbi | Category: Motorcycle | Size: 20 MB

Table of Contents
2
Introduction
4
Safety Regulations
8
Maintenance Regulations
8
1 Special Tools for the Engine

8
- Safety Regulations
  9
- Maintenance Regulations
  10
- Special Tools for the Engine
  13
- Special Tools - Chassis
  16
- Technical Data
  17
- Standard Bolts and Screws
  26
- Tightening Torques
  26
2 PDI (Pre-Delivery Inspection)

30
- Checking the Assembly and Preparing the Machine for Delivery to the First Purchaser (PDI)
  31
- PDI (Pre-Delivery Inspection)
  31
- Delivery to Customer
  32
- Road Test Check
  32
- Location of Elements
  33
- Maintenance
  33
- Removing Bodywork Elements
  33
- Location of Elements
  34
- Maintenance
  34
- Removing Bodywork Elements
  36
  - Pillion Passenger Seat
    37
  - Cowling
    38
  - Cowling Top Cover
    38
  - Bottom Tank Cover
    39
  - Bottom Fairing
    40
  - Cylinder Head Protective Cover
    40
  - Front Mudguard
    41
  - Silencer End Cover
    41
  - Cowling Side Closing Cover
    42
  - Top Tank Cover
    42
  - Front Bubble Screen
    43
  - Radiator Air Ducting
    43
  - Central Front Fairing
    44
  - Fuel Tank
    46
  - Rear Mudguard
    46
  - Bottom Cowling Closing Cover
    47
  - Rear Mudguard Supplement
    47
3 Periodical Maintenance Table

48
- Lubrication Points
  51
- Inspection and Maintenance
  52
  - Adjusting the Timing Chain Play
    52
  - Transmission Chain
    53
  - Fitting a New Transmission Kit
    54
  - Inspecting the Exhaust System
    55
  - Inspecting the Ais Valve (Secondary Air)
    55
  - Air Filter Renewal
    56
  - Air Filter Box Drain Plug
    56
  - Inspecting the Spark Plug
    57
  - Adjusting the Clutch Lever
    58
  - Adjusting Idle Speed (Idle Speed)
    58
  - Adjusting the Throttle Cable
    59
  - Adjusting the Gear Lever
    60
  - Adjusting the Front Brake
    61
  - Adjusting the Rear Brake
    62
  - Inspecting the Front Brake Pads
    63
  - Renewing the Front Brake Pads
    63
  - Inspecting the Rear Brake Pads
    65
  - Renewing the Rear Brake Pads
    65
  - Inspecting the Tyres
    67
  - Inspecting the Coolant Level
    68
  - Recommended Coolant
    68
  - Changing the Engine Oil
    69
  - Recommended Engine Oil
    69
  - Quantity of Engine Oil
    69
  - Inspecting the Engine Oil Level
    70
  - Recommended Oil for the Engine
    70
  - Adjusting the Valve Settings
    71
  - Adjusting Valve Settings that Are Outside that Specified
    73
  - Measuring the Compression Pressure
    79
  - Resetting Service Indicator
    80
- Maintenance Pieces
  83
- Identification of Sets
  84
- Removing the Engine from the Frame
  84
- Dismantling the Engine
  84
- Inspecting the Engine Elements
  84
  - Identification of Sets
    85
  - Crankcase Location
    85
  - Crankcase Machined Diameter
    85
  - Balance Shaft – Gear Set
    85
  - Primary Shaft - Gear Set
    86
  - Distances between Gears
    86
  - Half-Bearing
    87
  - Valve Guides
    88
  - Cylinder and Piston Sets
    88
  - Removing the Engine from the Frame
    89
  - Dismantling the Engine
    91
  - Inspecting the Engine Elements
    104
  - Checking for Tight Valve Seating
    104
  - Steps to Follow to Dismantle the Valves
    104
  - Valve Grinding
    106
  - Valves, Valve Guides and Valve Springs
    109
  - Inspecting the Camshaft
    110
  - Timing Chain, Sprockets and Rollers
    111
  - Inspecting the Clutch Bell Housing
    115
  - Inspection of the Forks and Gear Selector
    115
  - Inspecting the Oil Pump
    117
  - Inspecting the Oil Passages (Right Hand Side Casing Cover)
    118
  - Bearings and Retaining Rings
    118
  - Locking Rings and Washers
    118
  - Assembling the Engine
    119
  - Drive Shaft Spare Parts
    119
- Assembling the Engine
  120
  - Crankshaft Parts
    121
  - Magneto Parts
    123
  - Gear Change Selector Parts
    126
  - Oil Pump Assembly Parts
    128
  - Clutch Bell Housing Parts
    133
  - Clutch Cover Parts
    136
  - Cylinder Head and Cylinder Parts
    138
  - Calculating the Bottom Gasket Thickness
    141
  - Valves and Camshaft Parts
    142
  - Thermostat Parts
    149
- Fitting the Engine into the Frame
  150
- Fuel Supply System
  153
- Dismantling the Carburettor
  153
- Assembling the Carburettor
  153
  - Dismantling the Carburettor
    155
  - Assembling the Carburettor
    160
5 Checking Level of the Float Chamber

164
- Checking the Vacum Valve and Tapered Needle
  164
- Checking the Automatic Choke
  166
- Cooling System
  168
- Diagram of the System
  168
- Description of the System and Checking of Elem
  168
- Renewing the Water Pump Oil Seal
  168
- Diagram of the System
  169
- Descripción of the Lubrication System
  178
  - Descripcion of the Lubrication System
    181
  - Chassis
    184
- Inspecting the Wheels
  184
- Inspecting the Wheels
  185
- Chassis
  185
- Front Wheel
  187
- Fitting the Front Wheel
  188
8 Front Suspension

189
- Inspecting the Front Forks
  191
- Fitting Front Suspension
  192
- Inspecting the Steering Column
  195
- Steering
  195
  - Dismantling the Semi-Handlebars
    196
  - Left-Hand Semi-Handlebar
    196
  - Right-Hand Semi-Handlebar
    196
  - Fitting the Semi-Handlebars
    197
  - Fitting the Semi-Handlebars Assembly
    197
- Rear Wheel
  198
  - Fitting the Rear Wheel
    199
  - Inspecting the Rear Suspension
    200
  - Fitting the Rear Suspension
    201
  - Braking System
    202
- Front Brake
  202
- Rear Brake
  202
  - Dismantling Brake Calliper
    203
  - Fitting the Brake Calliper
    203
  - Front Brake
    203
  - Removing the Front Wheel Cylinder
    204
  - Fitting the Front Brake Wheel Cylinder
    205
  - Checking the Brake Calliper Main Cylinder
    206
  - Checking the Brake Lever Master Cylinder
    206
  - Extracting the Front Brake Disk
    206
  - Fitting the Front Brake Disk
    207
  - Wear to the Front Brake Disk
    207
  - Bleeding the Brake System Pipe
    208
  - Front Brake Disk Distortion
    208
  - Assembling Brake Calliper
    211
  - Dismantling the Brake Calliper
    211
  - Rear Brake
    211
  - Dismantling the Rear Brake Cylinder
    212
  - Fitting the Rear Brake Wheel Cylinder
    213
  - Checking the Brake Lever Master Cylinder (Visual Check)
    214
  - Extracting the Rear Brake Disk
    214
  - Fitting the Rear Brake Disk
    215
  - Wear to the Rear Brake Disk
    215
  - Rear Brake Disk Distortion
    216
  - Electrical System
    220
- General Indications
  220
- Locating Electrical Components
  220
- Wiring Diagram
  220
- Checking Connectors
  221
- Electrical System
  221
- General Indications
  221
- Switch Connections Shown in this Manual
  222
- Locating Electrical Components
  223
- Wiring Diagram - GPR 125 4T
  224
- Charging System
  225
- Current Leakage
  225
10 Ignition System

226
- Description of Components
  226
- Description of the System
  226
- Starter Motor System
  227
- Instrument Panel
  228
  - Adjusting the Time
    229
  - Measuring the Time
    229
  - Resetting the Trip Meter Values
    229
  - Using the Chronometer
    229
  - Connections
    231
  - Adjusting the Headlight Beam (Right-Left)
    235
  - Changing the Headlight
    235
  - Changing the Headlight Bulbs
    235
- Lighting and Indicating
  235
  - Changing the Sidelight
    236
  - Dismantling
    236
  - Changing the Rear Light
    237
  - Changing the Horn
    239
  - Changing the Turn Indicator Bulbs
    239
  - Changing the Number Plate Light
    240
  - Changing the Diode
    241
  - Changing the Regulator
    241
- Fitting New Components
  241
  - Changing the CDI Unit
    242
  - Changing the Starter Relay
    242
  - Changing the Instrument Panel
    243
  - Changing the Main Relay
    243
  - Changing the HT Coil
    244
- Inspecting the Battery and Fuses
  245
- Inspecting the Fuses
  246

Derbi GPR 125 Racing Workshop Manual (146 pages)

Brand: Derbi | Category: Motorcycle | Size: 5 MB

Contents
4
Safety Regulations
5
Maintenance Regulations
5
Vehicle Identification
6
Racing 125 General Technical Data
7
Preparation for Removal and Dismantling
8
Spare Parts
9
Seals, Retaining Rings and O-Rings
9
Tab Washers/Spacers and Split Pins
9
Bearings and Retaining Rings
9
Locking Rings
10
Special Tools
10
Maintenance Specifications
12
General Specifications
12
Maintenance Specifications
13
Engine Specifications
14
Engine Tightening Torques
16
Chassis Specifications
18
Electrical System Specifications
20
General Tightening Torque Specifications
22
Chassis Tightening Torques
23
Periodic Maintenance / Lubrication Intervals
25
Periodic Inspections and Adjustments
26
Seats, Fairing and Fuel Tank
27
Dismantling
27
Refitting
28
Engine
29
CO Measurement and Vacuum Running Adjustment
29
Adjusting the Throttle Cable
30
Inspecting the Spark Plug
31
Inspecting the Engine Oil Level
33
Recommended Oil for the Engine
33
Changing the Engine Oil
33
Inspecting the Exhaust System
34
Renewing Air Filter
34
Adjuting the Clutch
35
Adjusting the Front Brakes
36
Adjusting the Rear Brakes
36
Inspecting the Brake Pads
36
Adjusting the Timing Chain Tension
37
Inspecting the Tires
38
Inspecting and Tightening the Spokes
40
Inspecting the Wheels
40
Inspecting the Battery
40
Electrical System
41
Inspecting the Fuses
41
Adjusting the Headlight Beam
43
Replacing the Headlight Bulbs
43
Changing Turn Indicator Bulbs
44
Changing the Side and Brake Light Bulbs
44
Inspecting the Engine
45
Dismantling the Engine
45
Dismantling the Side Covers and Fuel Tank
45
Engine on
45
Removing the Engine from the Chassis
46
Cylinder Head, Cylinder and Piston
49
Dismantling the Reed Valve
50
Magneto
50
Clutch
51
Gear Change Shaft
54
Crankcase
54
Balancer, Transmission and Gear Selector
55
Crankshaft
56
Cylinder Head
56
Cylinder and Piston
57
Inspection and Repair
58
Inspecting the Piston Rings
59
Inspecting the Balancer
60
Inspecting the Clutch Bell Housings
61
Inspecting the Clutch
61
Inspecting the Actioning Rod
63
Inspection of the Forks and Gear Selector
63
Crankcases
65
Locking Rings and Washers
65
Reassembling the Engine and Making Adjustments
66
Valves, Rockers and Camshaft
66
Crankshaft and Balancer Shaft
67
Transmission
68
Gear Selector
69
Clutch and Clutch Bell Housing
74
Installing the Clutch Bell Housing
75
Fitting the Clutch
75
Magneto and Starter Systems
78
Inspecting the Starter Gear
79
Magneto and Starter Gear
79
Cylinder, Piston, Cylinder Head and Exhaust Valve
81
Fitting Piston Rings, Piston and Cylinder
82
Fitting the Cylinder Head
83
Fitting the Reed Valve
84
Refitting Engine into the Frame
85
Carburetor
89
Adjusting the Fuel Level
95
Front Wheel Diagram
96
Chassis - Front Wheel and Brakes
97
Inspecting the Front Wheel
97
Inspecting the Speedometer
99
Dismantling the Front Disk Calliper
99
Assembling the Front Wheel
105
Rear Wheel and Brakes
107
Wheel Diagram
107
Brake Diagram
108
Rear Wheel and Brakes Dismantling
109
Dismantling the Rear Disk Calliper
109
Inspecting the Rear Wheel
116
Fitting the Rear Wheel
116
Transmission Dismantling
117
Inspecting the Drive Chain
118
Chain Sprocket
118
Fitting the Chain Sprocket and the Drive Chain
119
Fork
120
Dismantling Front Suspension
121
Inspecting the Front Forks
123
Handlebars
126
Handlebars Dismantling
127
Inspecting the Half Handlebars
128
Dismantling the Steering Column
128
Inspecting the Steering Column
128
Fitting the Half Handlebars
129
Shock Absorber and Swinging Arm
130
Shock Absorber and Swinging Arm Dismantling
131
Shock Absorber and Swinging Arm Inspection
131
Electrical System
132
Electrical System: Checking Connectors
135
Inspecting the Switches
136
Connections for the Switches Shown in this Manual
136
Troubleshooting
137

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Derbi GPR 125 Racing Manuals

Derbi GPR 125 Racing Workshop Manual (248 pages)

Table of Contents

1 Special Tools for the Engine

2 PDI (Pre-Delivery Inspection)

3 Periodical Maintenance Table

5 Checking Level of the Float Chamber

8 Front Suspension

10 Ignition System

Derbi GPR 125 Racing Workshop Manual (146 pages)

Table of Contents

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Derbi Categories