Gilera Runner RSTPurejet Manuals

Manuals and User Guides for Gilera Runner RSTPurejet. We have 1 Gilera Runner RSTPurejet manual available for free PDF download: Service Manual

Gilera Runner RSTPurejet Service Manual (235 pages)

Brand: Gilera | Category: Scooter | Size: 8.9 MB

Index of Topics
5
Characteristics
7
Safety Rules
8
Maintenance Rules
8
Vehicle Identification
8
Dimensions and Mass
9
Size and Weight
9
Engine
9
Capacities
10
Electrical System
10
Frame and Suspensions
10
Brakes
10
Wheels and Tyres
11
Tightening Torques
11
Steering Assembly
11
Frame Assembly
11
Front Suspension
12
Front Brake
12
Rear Brake
12
Engine Assembly
12
Overhaul Data
13
Assembly Clearances
13
Cylinder - Piston Assy.
13
Piston Rings
14
Crankcase - Crankshaft - Connecting Rod
14
Sealing Rings
14
Axial Play Connecting Rod - Crankshaft
14
Piston - Test Probe
15
Slot Packing System
16
Products
16
Table of Recommended Products
16
Tooling
19
Maintenance
31
Maintenance Chart
32
Every 2 Years
32
At 1,000 Km
32
At 5,000 Km , 25,000 Km , 35,000 Km , 55,000 Km
32
At 15,000 Km, 45,000 Km
33
At 20,000 Km, 40,000 Km
33
At 30.000 Km
33
Spark Plug
34
Hub Oil
35
Air Filter
36
Fuel Filter
36
Transmissions
37
Transmission Adjustment
37
Mixer Timing
38
Cooling System
38
Level Check
38
Headlight Adjustment
39
Troubleshooting
41
Engine Overheating
42
Clutch Grabbing or Performing Inadequately
42
Insufficient Braking
42
Brakes Overheating
43
Battery
43
Overheating Brakes
43
Heavy Steering
44
Excessive Steering Play
44
Noisy Suspension
44
Suspension Oil Leakage
44
Wiring Diagram
46
Ignition
48
Headlights and Automatic Starter Section
49
Battery Recharge and Starting
50
Level Indicators and Enable Signals Section
51
Electronic Central Unit
52
Turn Signal Lights
52
Instruments and Warning Lights Control Board
53
Checks and Inspections
54
Battery Recharge Circuit
54
Stator Check
54
Voltage Regulator Check
55
Recharge System Voltage Check
55
Starter Motor
55
Turn Signals System Check
57
Level Indicators
57
Lights List
57
Dry-Charge Battery
58
Checking Electrolyte Density
59
Battery Maintenance
59
Specific Tooling
60
Cleaning the Battery
60
Engine from Vehicle
61
Removal of the Engine from the Vehicle
62
Automatic Transmission
68
Transmission Cover
68
Removing the Driven Pulley Shaft Bearing
68
Refitting the Driven Pulley Shaft Bearing
68
Removing the Driven Pulley
69
Inspecting the Clutch Drum
69
Removing the Clutch
69
Inspecting the Clutch
70
Pin Retaining Collar
70
Removing the Driven Half-Pulley Bearing
71
Inspecting the Driven Fixed Half-Pulley
72
Inspecting the Driven Sliding Half-Pulley
72
Refitting the Driven Half-Pulley Bearing
73
Refitting the Driven Pulley
73
Inspecting the Clutch Spring
74
Refitting the Clutch
74
Drive-Belt
75
Removing the Driving Pulley
75
Inspecting the Rollers Case
76
Refitting the Driving Pulley
77
End Gear
78
Removing the Hub Cover
78
Removing the Wheel Axle
78
Removing the Wheel Axle Bearings
78
Inspecting the Hub Shaft
79
Refitting the Wheel Axle Bearing
80
Refitting the Ub Cover
81
Flywheel Cover
81
Removing the Stator
81
Refitting the Stator
82
Refitting the Flywheel Cover
83
Cylinder Assy. and Timing System
83
Removing the Cylinder Head
84
Removing the Cylinder - Piston Assy.
86
Inspecting the Small End
87
Inspecting the Wrist Pin
87
Inspecting the Piston
87
Inspecting the Cylinder
88
Inspecting the Piston Rings
88
Removing the Piston
89
Choosing the Gasket
90
Refitting the Head and Timing System Components
91
Splitting the Crankcase Halves
94
Removing the Crankshaft
95
Removing the Crankshaft Bearings
95
Refitting the Crankshaft Bearings
96
Inspecting the Crankshaft Components
97
Inspecting the Crankshaft Alignment
97
Inspecting the Crankcase Halves
98
Refitting the Crankshaft
99
Air Compressor
101
Removing Air Compressor
101
Overhaul
102
Check Air Compressor
102
Refit Air Compressor
103
Lubrication
104
Crankshaft Oil Seals
104
Oil Pump
105
Suspensions
107
Removing the Front Wheel
108
Front Wheel Hub Overhaul
108
Refitting the Front Wheel
110
Removing the Rear Wheel
110
Refitting the Rear Wheel
110
Shock Absorbers
110
Centre-Stand
111
Expulsion of Kickstand Bracket Fastening Pin
111
Fitting and Caulking the Kickstand Pin to the Bracket
111
Replacing Complete Kickstand
111
Pure Jet Injection
113
EMS Injection System
114
Precautionary Measures
115
Suggestions for Diagnosis
116
Troubleshooting
116
Dirty Fuel Filter
117
Autodiagnosis
117
Auto-Diagnostic
118
Menu of the Diagnostic Tester
118
Parameters
120
Active Diagnostics
123
Cpu Power Circuit
124
Injection Ecu Power Supply Circuit
124
Diagnosis Tester Connection Circuit
129
Components Layout
129
Throttle Position Sensor Circuit (T.P.S.)
131
T.P.S. Signal Reset
137
Automatic T.P.S. Reset
137
Connect the Scooter Diagnostic Tester
138
Carry out the Manual Reset Procedure
138
Manual T.P.S. Reset
138
Rpm-Timing Sensor Circuit
140
TPS Resetting Successful
140
020481Y Control Unit Interface Wiring
142
H.T. Coil Circuit
145
Circuit Diagnosis
146
Checking the Electric Circuit
147
Restore the Wiring
148
Ignition Timing Check
150
Compressed Air System
151
Air Injector Circuit
153
Fuel Pump Circuit
158
Control Unit Interface Wiring
160
Petrol Injector Circuit
162
Coolant Temperature Sensor Circuit
166
Diagram of Fuel Supply System
166
Fuel Pressure Control Kit
168
Braking System
175
Rear Brake Calliper
176
Front Brake Calliper
176
Rear Brake Disc
177
Refitting Front Brake Calliper
177
Front Brake Disc
178
Disc Inspection
179
Front Brake Pads
179
Fill
180
Front
180
Front Brake Pump
181
Water Pump - Overhaul
184
Water Pump Impeller Stop
184
Chassis
189
Seat
190
Rear Handlebar Cover
190
Front Handlebar Cover
190
Headlight Assy.
191
Frame Central Cover
191
Legshield
192
Knee-Guard
193
Removing the Ignition Key-Switch When on *Off*
194
Front Central Cover
194
Removing the Ignition Key-Switch When on *Lock*
194
Front Wheel Housing
195
Taillight Assy.
195
Footrest
195
Side Fairings
196
Helmet Bay
197
Fuel Tank
198
Front Mudguard
198
Radiator Fan
199
Expansion Tank
199
Mixture Oil Tank
199
Lower Cover
200
Pre-Delivery
203
Aesthetic Inspection
204
Tightening Torques Inspection
204
Levels Check
205
Road Test
205
Static Test
206
Functional Inspection
206
Time
207
Crankcase
209
Crankshaft
210
Cylinder Assy.
211
Cylinder Head Assy.
212
Driven Pulley
214
Driving Pulley
216
Water Pump
218
Flywheel Magneto
220
Belt Cooling Duct
221
Butterfly Valve
222
Exhaust Pipe
223
Air Cleaner
224
Mudguard
225
Radiator
226
Rear Shock-Absorber
227
Steering Column Bearings
228
Handlebar Components
229
Swing-Arm
230
Compressore Aria
231
Brake Callipers
232

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Gilera Runner RSTPurejet Service Manual (235 pages)

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