PIAGGIO 633938(PT) Manuals

Manuals and User Guides for PIAGGIO 633938(PT). We have 1 PIAGGIO 633938(PT) manual available for free PDF download: Service Station Manual

PIAGGIO 633938(PT) Service Station Manual (315 pages)

Brand: PIAGGIO | Category: Scooter | Size: 27 MB

Index of Topics
5
Characteristics
7
Safety Rules
8
Maintenance Rules
8
Vehicle Identification
9
Dimensions and Mass
9
Weights and Dimensions
9
Data
10
Capacities
10
Electrical Components
10
Electrical System
10
Frame and Suspensions
11
Brakes
11
Wheels and Tyres
11
Tyre Pressure
11
Tightening Torques
12
Rear Suspension
12
Front Brake
13
Rear Brake
13
Muffler
13
Lubrication
13
Engine - Transmission
14
Engine - Flywheel
14
Crankcase and Crankshaft
14
Engine - Cooling
14
Assembly Clearances
14
Cylinder - Piston Assy
15
Engine Coupling Categories
15
Crankcase - Crankshaft - Connecting Rod
16
Crankshaft/ Crankcase Axial Clearance
16
Slot Packing System
16
Tooling
21
Index of Topics
21
Appropriate Tool
22
Maintenance
35
Index of Topics
35
Maintenance Chart
36
Every 2 Years
36
Every 3.000 Km
36
Carburettor
40
Checking the Spark Advance
40
Spark Plug
42
Hub Oil
43
Air Filter
44
Engine Oil
45
Checking the Ignition Timing
47
Checking the Valve Clearance
47
Headlight Adjustment
48
SAS Filters Inspection and Cleaning
48
Troubleshooting
53
Index of Topics
53
Poor Performance
54
Starting Difficulties
54
Difficult Starting
54
Excessive Oil Consumption/Exhaust Smoke
55
Insufficient Lubrication Pressure
55
Poor Lubrication Pressure
55
Engine Tends to Cut-Off at Full Throttle
56
Engine Tends to Cut-Off at Idle
56
Engine Stop Idling
56
Excessive Exhaust Noise
56
High Fuel Consumption
57
SAS Malfunctions
57
Transmission and Brakes
57
Clutch Grabbing or Performing Inadequately
57
Insufficient Braking
58
Brakes Overheating
58
Electrical System
58
Turn Signal Lights Malfunction
58
Rear Wheel
59
Rear Wheel Rotates with Engine at Idle
59
Steering Controls and Suspensions
59
Electrical System
61
Conceptual Diagrams
65
Ignition
65
Battery Recharge and Starting
66
Level Indicators and Enable Signals Section
67
Devices and Accessories
68
Lights and Turn Indicators
70
Checks and Inspections
71
Immobiliser
71
Virgin Circuit
73
Diagnostic Codes
73
Diagnostic Code - 2 Flashes
74
Ignition Circuit
74
No Spark Plug
75
HV Primary Coil Check
75
HV Coil Secondary Check
75
Pick-Up
76
H.V. Coil
76
Battery Recharge Circuit
77
Stator Check
77
Voltage Regulator Check
78
Recharge System Voltage Check
79
Choke Inspection
79
Lights List
80
Light Bulbs Table
80
Fuses
81
Fuse Chart
81
Dashboard
82
Sealed Battery
83
Voltage Check
83
Constant Voltage Battery Charge Mode
83
Constant Current Battery Charge Mode
84
Dry-Charge Battery
84
Commissioning a New Dry-Charged Battery
84
Connectors
85
20-Way Instrument Connector
85
12-Way Instrument Connector
86
Remote Seat Opening
86
Zeroing
86
Engine from Vehicle
89
Index of Topics
89
Exhaust Assy. Removal
90
Removal of the Engine from the Vehicle
91
Engine
95
Automatic Transmission
96
Transmission Cover
96
Air Duct
96
Removing the Driven Pulley Shaft Bearing
97
Refitting the Driven Pulley Shaft Bearing
97
Removing the Driven Pulley
98
Inspecting the Clutch Drum
98
Removing the Clutch
99
Clutch Removal
99
Inspecting the Clutch
100
Pin Retaining Collar
100
Removing the Driven Half-Pulley Bearing
101
Inspecting the Driven Fixed Half-Pulley
101
Inspecting the Driven Sliding Half-Pulley
102
Movable Driven Half-Pulley Dimensions
102
Refitting the Driven Half-Pulley Bearing
103
Refitting the Driven Pulley
103
Inspecting the Clutch Spring
105
Refitting the Clutch
105
Drive-Belt
107
Removing the Driving Pulley
107
Inspecting the Rollers Case
108
Refitting the Driving Pulley
109
Refitting the Transmission Cover
110
End Gear
111
Removing the Hub Cover
111
Removing the Wheel Axle
111
Removing the Hub Bearings
111
Removing the Wheel Axle Bearings
112
Inspecting the Hub Shaft
113
Inspecting the Hub Cover
113
Refitting the Wheel Axle Bearing
114
Refitting the Hub Cover Bearings
115
Refitting the Hub Bearings
115
Refitting the Ub Cover
116
Flywheel Cover
117
Removing the Stator
117
Refitting the Stator
118
Refitting the Flywheel Cover
118
Flywheel and Starting
118
Removing the Flywheel Magneto
119
Inspecting the Flywheel Components
119
Refitting the Flywheel Magneto
119
Refitting the Starter Motor
120
Cylinder Assy. and Timing System
120
Removing the Intake Manifold
120
Removing the Rocker-Arms Cover
121
Removing the Timing System Drive
121
Removing the Cam Shaft
123
Removing the Cylinder Head
124
Removing the Valves
124
Removing the Cylinder - Piston Assy.
124
Inspecting the Small End
126
Inspecting the Wrist Pin
127
Inspecting the Piston
129
Removing the Piston
129
Choosing the Gasket
130
Refitting the Piston Rings
131
Refitting the Cylinder
132
Inspecting the Cylinder Head
132
Inspecting the Timing System Components
133
Inspecting the Valve Sealings
133
Inspecting the Valve Housings
134
Inspecting the Valves
134
Inspecting the Springs and Half-Cones
136
Refitting the Valves
136
Inspecting the Cam Shaft
137
Refitting the Head and Timing System Components
138
Insert the Spacer on the Cam Shaft
139
Fit the End-Of Stroke Ring on the Valve-Lifting Mass
139
Set the Tensioner Cursor to the Rest Position
140
Timing System Components Assembly
140
Refitting the Rocker-Arms Cover
142
Refitting the Intake Manifold
142
Crankcase - Crankshaft
142
Splitting the Crankcase Halves
142
Fitting Clearance
144
Check the Radial Clearance on the Connecting Rod
144
Inspecting the Crankshaft Alignment
145
Standard Diameter
145
Inspecting the Crankcase Halves
147
Inspecting the Crankshaft Plain Bearings
148
Refitting the Crankcase Halves
150
Studs
150
Oil Pressure Check
153
Crankshaft Oil Seals
153
Oil Pump
155
Removing the Oil Sump
155
Inspecting the By-Pass Valve
156
Refitting the Oil Sump
156
SAS Valve
157
Inspecting the One-Way Valve
157
Inspecting the Cut-Off
158
Fuel Supply
159
Removing the Carburettor
159
Level Check
168
Inspecting the Valve and Needle
168
Inspecting the Automatic Choke Device
169
Adjusting the Idle
171
Suspensions
173
Index of Topics
173
Removing the Front Wheel
174
Front Wheel Hub Overhaul
174
Handlebar
176
The Tilt Mechanism
176
Hydraulic System Layout
177
Steering Tubes
177
Parallelogram Device
183
Geared Motor and Suspension Locking System
188
Geared Motor
205
Potentiometer
206
Tilt Locking-Unlocking Switch
207
Rider Presence Sensor
214
Wheel Alignment
215
Tool Fitting
215
Removing the Rear Wheel
219
Refitting the Rear Wheel
220
Shock Absorbers
226
Centre-Stand
227
Braking System
229
Index of Topics
229
Rear Brake Calliper
230
Brake Pipes
232
Front Brake Pipes Removal
233
Parking Brake
234
Cooling System
237
System Bleed
238
Chassis
239
Seat
240
Front Handlebar Cover
240
Headlight Assy.
241
Frame Central Cover
242
Legshield
243
Knee-Guard
243
Taillight Assy.
246
Footrest
246
Side Fairings
247
License Plate Holder
248
Helmet Bay
248
Spoiler
249
Fuel Tank
250
Top-Case
252
Rear
252
Handles and Top Side Fairings
252
Radiator Cover
253
Pre-Delivery
255
Aesthetic Inspection
256
Tightening Torques Inspection
256
Lock Check
256
Safety Locks
256
Levels Check
257
Road Test
258
Static Test
258
Functional Inspection
258
Time
261
Crankcase
263
Crankshaft
264
Cylinder Assy.
265
Cylinder Group
265
Cylinder Head Assy.
266
Rocker Arms Support Assy.
267
Cylinder Head Cover
268
Oil Filter
269
Driven Pulley
270
Oil Pump
271
Final Gear Assy.
272
Driving Pulley
273
Transmission Cover
274
Water Pump
275
Starter Motor
276
Electrical Start up
276
Flywheel Magneto
277
Exhaust Pipe
279
Air Cleaner
280
Frame
281
Legshield Spoiler
283
Rear Cover
285
Rear Shield
285
Central Cover
286
Mudguard
287
Rear Shock Absorber
289
Handlebar Covers
290
Handlebar Components
291
Swinging Arm
292
Instrument Panel
294
Locks
295
Turn Signal Lights
295
Front Wheel
298
Rear Wheel
299
Electric Devices
300
Electronic Controls
302
Front Suspension
306
Cooling System
307
Braking System
308
Secondary Air Box
310
Windshield
310
Stickers
311

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PIAGGIO 633938(PT) Service Station Manual (315 pages)

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