Derbi boulevard 125 4t Workshop Manual Download Page 1

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WORKSHOP MANUAL

BOULEVARD 125 4T

Summary of Contents for boulevard 125 4t

Page 1: ...WORKSHOP MANUAL BOULEVARD 125 4T ...

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Page 3: ...ons of this manual relating to specific tools along with the specific tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely observe these i...

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Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...ay that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original DERBI spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing r...

Page 8: ...ZAPM42100 1001 Engine prefix 125 M421M 1001 Chassis prefix 150 ZAPM42200 1001 Engine prefix 150 M422M 1001 Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Dry weight 112 kg Overall height 1150 mm Seat height 785 Width 735 Wheel base 1330 Lenght 1870 Characteristics CHAR 8 ...

Page 9: ...15 Bore x stroke 125 57 x 48 6 mm Bore x stroke 62 6 x 48 6 mm Cubic capacity 125 124 cm Cubic capacity 150 46 cm Compression ratio 125 10 6 1 Compression ratio 10 5 1 Carburettor KEIHIN CVEK26 Engine idle speed approx 1600 1800 rpm Start up Electric Maximum power to crankshaft 125 10 5 CV at 8000 rpm Max power 11 6 hp at 7750 rpm Cooling Forced air circulation Characteristics CHAR 9 ...

Page 10: ...RICAL COMPONENTS Specification Desc Quantity Start up Electric Spark plug 125 Champion RG6YC NGK CR7EB Spark plug Champion RG6YC Frame and suspensions FRAME AND SUSPENSION Specification Desc Quantity Chassis Steel tube chassis Front suspension Ø 32 Hydraulic telescopic fork travel 76 mm Rear suspension Single hydraulic shock absorber with spring pre load adjustable on 4 positions 64 mm travel Brak...

Page 11: ...ary air system SAS This system allows more oxygen to be added to the unburned gases before they reach the con verter thus improving the action of the catalytic converter The air enters the exhaust duct from the head and is purified by a black filter The system is fitted with a control valve that disa bles operation while decelerating to avoid unwan ted noise To ensure the best functioning of the S...

Page 12: ...e adjustment screw initial opening 1 Starter jet 42 Starter air jet on the body Ø 1 5 Starter pin travel 10 mm at 24 Starter resistance 20 Ohm at 24 150cc Version Kehin CARBURETTOR SETTING Specification Desc Quantity Type CVEK26 Throttle valve diameter Ø 26 5 Diffuser diameter Ø 26 4 Setting stamping 265A Maximum jet 82 Maximum air jet on the body 85 Tapered pin stamping NELA Throttle valve spring...

Page 13: ...5 Flywheel cover screw 1 2 Flywheel air manifold screw 3 4 Pressure reducer counterweight retainer 7 8 5 Camshaft pulley screw 12 14 Timing chain tensioner slider screw 10 14 Starter ground support screw 11 15 Tensioner screws 11 13 Timing chain tensioner central screw 5 6 Camshaft retention plate screw 5 6 Nut fixing muffler to cylinder head 16 18 Head intake manifold screw 11 13 TRANSMISSION Nam...

Page 14: ...ame Torque in Nm Engine arm bolt frame arm 33 41 Engine swinging arm bolt 33 41 Frame arm engine arm bolt 60 64 Centre stand pin 32 40 Bolts mounting rocker arm silent block 36 44 FRONT SUSPENSION Name Torque in Nm Lower fork fixing screw 15 20 Front wheel axle nut 45 50 FRONT BRAKE Name Torque in Nm Brake fluid pump hose fitting 16 20 Nm Brake fluid tube calliper fitting 19 24 Calliper tightening...

Page 15: ... D2 63 001 63 008 62 954 62 961 0 040 0 054 Coupling 3rd over size A3 63 180 63 187 63 133 63 140 0 040 0 054 Coupling 3rd over size B3 63 187 63 194 63 140 63 147 0 040 0 054 Coupling 3rd over size C3 63 194 63 201 63 147 63 154 0 040 0 054 Coupling 3rd over size D3 63 201 63 208 63 154 63 161 0 040 0 054 COUPLING BETWEEN RIGHT WAY PISTON AND CYLINDER 150 Name Initials Cylinder Piston Play on fit...

Page 16: ...ston Play on fitting Coupling M 56 997 57 004 56 944 56 951 0 046 0 060 Coupling N 57 004 57 011 56 951 56 958 0 046 0 060 Coupling O 57 011 57 018 56 958 56 965 0 046 0 060 Coupling P 57 018 57 025 56 965 56 972 0 046 0 060 Coupling 1st over size M1 57 197 57 204 57 144 57 151 0 046 0 060 Coupling 1st over size N1 57 204 57 211 57 151 57 158 0 046 0 060 Coupling 1st over size O1 57 211 57 218 57 ...

Page 17: ...e 57 6x1 A 0 10 0 30 Oil scraper ring 3rd oversize 57 6x2 5 A 0 10 0 35 Maximum clearance after use 1 mm SEALING RINGS 150 Name Description Dimensions Initials Quantity Compression ring 62 6x1 A 0 15 0 30 Oil scraper ring 62 6x1 A 0 20 0 40 Oil scraper ring 62 6x2 5 A 0 20 0 40 Compression ring 1st oversize 62 8x1 A 0 15 0 30 Oil scraper ring 1st oversize 62 8x1 A 0 20 0 40 Oil scraper ring 1st ov...

Page 18: ...iption Dimensions Initials Quantity Crankshaft Category 1 28 998 29 004 Crankshaft Class 2 29 004 29 010 Crankcase Category 1 32 953 32 959 Crankcase Category 2 32 959 32 965 Crankshaft half bearing Category B blue 1 973 1 976 Crankshaft half bearing Type C yellow 1 976 1 979 Crankshaft half bearing Category E green 1 979 1 982 Crankshaft catego ry 1 Crankcase category 1 E E Crankshaft catego ry 1...

Page 19: ...he dial gauge rotation Calculate the difference between the two measurements use the chart below to identify the thickness of the cylinder base gasket to be used for refitting By correctly identifying the cylinder base gasket thickness an adequate compression ratio is maintained Remove the specific tool and the cylinder Characteristic Compression ratio 125 10 6 1 Compression ratio 10 5 1 SHIMMING ...

Page 20: ...TY HI TEC 4T Oil to lubricate flexible transmis sions brakes throttle control and odometer Oil for 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AGIP GP 330 Grease brake control levers throttle grip Calcium complex soap based grease with NLGI 2 ISO L XBCIB2 AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Sy...

Page 21: ...INDEX OF TOPICS TOOLING TOOL ...

Page 22: ...ption 001330Y Tool for fitting steering seats 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bear ings 002465Y Pliers for circlips 005095Y Engine support 008564Y Flywheel extractor Tooling TOOL 22 ...

Page 23: ...Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge Tooling TOOL 23 ...

Page 24: ...litting strip 020263Y Sheath for driven pulley fitting 020287Y Clamp to assemble piston on cyl inder 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light for timing con trol Tooling TOOL 24 ...

Page 25: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger Tooling TOOL 25 ...

Page 26: ...Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47 mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide 020364Y 25 mm guide Tooling TOOL 26 ...

Page 27: ...ode Description 020368Y driving pulley lock wrench 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y011 adapter for valve removal tool 020409Y Multimeter adaptor Peak volt age detection Tooling TOOL 27 ...

Page 28: ...cription 020412Y 15 mm guide 020414Y 28 mm guide 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020425Y Punch for flywheel side oil seal 020426Y Piston fitting fork Tooling TOOL 28 ...

Page 29: ...Piston fitting band 020428Y Piston position check support 020430Y Pin lock fitting tool 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting removing the driv en pulley clutch Tooling TOOL 29 ...

Page 30: ...res code Description 020565Y Flywheel lock calliper spanner 020622Y Transmission side oil guard punch 494929Y Exhaust fumes analyser 020625Y Kit for sampling gas from the ex haust manifold Tooling TOOL 30 ...

Page 31: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 32: ...ck Vehicle and brake test test ride See instructions in the Idle speed adjustment section AT 6000 KM OR 12 MONTH 18000 KM 54000 KM 150 Action Engine oil replacement Hub oil level check Spark plug electrode gap check Air filter clean Engine oil change Oil filter net filter clean Valve clearance adjustment Variable speed rollers pads check Driving belt checking Brake pads check condition and wear Br...

Page 33: ... and brake test test ride See section Adjusting the idle speed AFTER 24000 KM AND AFTER 48000 KM 205 Action Engine oil replacement Hub oil change Air filter clean Engine oil change Oil filter net filter clean Spark plug replacement Idle speed adjustment Throttle lever adjustment Pads and variator rollers replacement Driving belt replacement Cylinder ventilation system cleaning Odometer gear greasi...

Page 34: ... oil change Spark plug replacement Air filter clean Engine oil change Oil filter net filter clean Valve clearance adjustment Idle speed adjustment Throttle lever adjustment Pads and variator rollers replacement Driving belt replacement Odometer gear greasing Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Flexible brake tubes replacemen...

Page 35: ...eaning Centre stand lubrication Tyre pressure and wear check Vehicle and brake test test ride See instructions in Idle speed adjustment section Checking the spark advance To check ignition advance use the stroboscopic light with induction pincers connected to the spark plug power wire Connect the induction pincers being careful to respect the proper polarity the arrow stamped on the pincers must b...

Page 36: ...cified Characteristic Ignition advance 150 check 10 1 at 2000 rpm 26 1 at 6000 rpm Ignition advance 125 check 15 1 at 2000 rpm 28 1 at 6000 rpm Spark advance variation ADVANCE VARIATION Specification Desc Quantity Operation threshold First threshold 9000 50 Second threshold 9300 50 Reactivation threshold First threshold 8900 50 Second threshold 9200 50 Spark elimination First threshold 1 spark on ...

Page 37: ...Maintenance MAIN 37 ...

Page 38: ...with the related warning light A A certain lowering of the level is caused by wear on the pads Top up Proceed as follows Remove the tank cap by loosening the two screws remove the gasket and top up using only the liquid specified without exceeding the maxi mum level CAUTION ONLY USE DOT 4 CLASSIFIED BRAKE FLUID CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES SKIN AND CLOTHING IN CASE OF AC...

Page 39: ...djustment Proceed as follows 1 Place the vehicle in running order and with the tyres inflated to the prescribed pressure on a flat surface 10 m away from a white screen situated in a shaded area making sure that the longitudinal axis of the scooter is perpendicular to the screen 2 Turn on the headlight and check that the bor derline of the projected light beam on the screen is not lower than 9 10 ...

Page 40: ...tion kit fitting onto the pipe as shown in the figure Correctly orientate the components as shown in the picture Shut the gas outlet on the tool Start the engine and let it warm up Shut the engine down Disconnect the SAS check valve vacuum hose shown in the figure Seal the connection using a conical a cap Maintenance MAIN 40 ...

Page 41: ...INED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS N B OTHERWISE CHECK THE FUEL LEVEL AD JUSTMENT IN THE TANK AND THE FUEL CIR CUIT N B IN CASE OF UNSTABLE CO CHECK THAT THE CARBURETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DE PRESSION SEALS WORK ADEQUATELY N B IN CASE OF 1000 PPM UNBURNED HYDRO CARBONS HC CHECK THE IGNITION SYS TEM THE TIMING SYSTEM THE VALVE CLEARANCE AND THE EXHAUST...

Page 42: ...he pho tograph the automatic starter cable harness and the carburettor to frame heater placed under the helmet compartment cover Lift the vehicle with a jack as shown in the figure to be able to reach the flywheel cover screws Remove the screw fixing the SAS valve to the flywheel cover indicated in the photograph Maintenance MAIN 42 ...

Page 43: ...S filter housing for dents or defor mations Clean the SAS filter carefully Replace the filter if it is damaged or deformed To refit carry out the removal operations but in re verse order CAUTION WHEN TRAVELLING ON DUSTY ROADS THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTE NANCE CHART CAUTION NEVER RUN THE ENGINE WITHOUT THE SEC ONDARY AIR FILTER Maintenance MAIN 43 ...

Page 44: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 45: ...el exceeds maximum Check for causes and fill to reach the correct level Excess of encrustations in the combustion cham ber Descale the cylinder the piston the head and the valves Incorrect timing or worn timing system elements Time the system again or replace the worn parts Muffler obstructed Replace Inefficient automatic transmission Check the rollers and the pulley movement re place the damaged ...

Page 46: ...rd then refill Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by applying a vacuum to the suction pipe Failing automatic starter on the carburettor Check the electrical wiring and mechanical move ment replace if necessary Start up enabling buttons failure Check continuity using an Ohm meter with the switch pressed replace if necessary Carburettor nozzles clogg...

Page 47: ...reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted Engine tends to cut off at idle THE ENGINE TENDS TO STOP AT IDLE SPEED Possible Cause Operation Incorrect idle adjustment Adjust using the rpm indicator Incorrect timing Time the system and check the timing system components The starter remains on Check electric wiring circuit not interrup...

Page 48: ...peration Worn brake pads or shoes Replace the brake pads or shoes and check for brake disk or drum wear conditions Front brake disk loose or deformed Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system there must be no flexible m...

Page 49: ... marked Follow the instructions in the ELEC TRICAL SYSTEM chapter for the recharging of the batteries Turn signal lights malfunction TURN INDICATOR NOT WORKING Possible Cause Operation Electronic ignition device failure With the key switch set to ON jump the contacts 1 Blue Black and 5 Orange on the control unit connector If by operating the turn indicator control the lights are not steadily on re...

Page 50: ... Possible Cause Operation Noisy suspension If the front suspension is noisy check that the front shock absorber works properly and the ball bearings are good condition Finally check the locking torque of the wheel axle nut the brake cal liper and the disc Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly Suspension oil leakage OIL LEAKAGE FR...

Page 51: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 52: ...choke and turn signal controls 4 Horn button 5 Turn signal switch 6 Headlight switch 7 Stop switch on rear brake 8 Double filament bulb 12V 55 60W 9 Front sidelight bulb 10 High beam warning light 11 Engine oil pressure warning light 12 Turn signal warning light L H Electrical system ELE SYS 52 ...

Page 53: ...ch 24 Front R H turn signal light 25 Wire harness 26 Fuel level sender 27 Fuse holder assembly 28 Rear R H turn signal light 29 License plate light bulb 30 License plate lamp 31 Battery 32 Starter relay 33 Starter motor 34 Engine oil pressure sensor 35 Pick up 36 Automatic choke device 37 Carburettor heater 38 H T coil 39 Taillight assembly 40 Stop and taillight bulb 41 Voltage regulator 42 Rear L...

Page 54: ...Grey Rs Pink R Red Vi Purple V Green VN Green Black BN White Black BBl White Blue GV Yellow Green Ar Orange Az Light Blue GrBl Gray Blue GrN Grey Black RBl Red Blue GR Yellow Red BlN Blue Black Electrical system installation Electrical system ELE SYS 54 ...

Page 55: ...ront side FRONT INSTALLATION 1 Specification Desc Quantity 1 Strap Insert the strap through the hole in the chas sis 2 Zip tie 3 Fixing Fold the chassis strap over the cables Electrical system ELE SYS 55 ...

Page 56: ...n Desc Quantity 1 Front R H turn signal light 2 Fuse holder box 3 Front L H turn signal light 4 Light remote control switch 5 Ignition key switch 6 Control device ignition 7 Immobiliser diagnostic outlet Electrical system ELE SYS 56 ...

Page 57: ...Specification Desc Quantity 8 Zip tie 9 Horn FRONT INSTALLATION 2 Specification Desc Quantity 1 Zip tie Electrical system ELE SYS 57 ...

Page 58: ... Desc Quantity 1 Cable harness fairlead 2 Breather tube 3 Heater conductors and automatic choke pro tective sheath 4 Voltage regulator 5 HV coil 6 Earth node 7 Starter remote control 8 License plate light connector Electrical system ELE SYS 58 ...

Page 59: ...STALLATION 1 Specification Desc Quantity 1 H T Cable 2 Zip tie 3 To the automatic choke device 4 To the heater 5 Rear R H turn signal light 6 Taillight 7 Rear L H turn signal light Electrical system ELE SYS 59 ...

Page 60: ...REAR INSTALLATION 2 Specification Desc Quantity 1 Zip tie 2 Starter motor earth 3 Starter motor positive outlet 4 Flywheel connection Conceptual diagrams Electrical system ELE SYS 60 ...

Page 61: ...Ignition IGNITION Specification Desc Quantity 1 electronic control unit 2 Magneto flywheel 3 Pick up 4 HV coil 5 Spark plug 6 Voltage regulator Electrical system ELE SYS 61 ...

Page 62: ...Battery 12V 9Ah 7 Headlamp relay 8 Light switch 9 High beam fuse 7 5A 10 Low beam and dashboard lights fuse 7 5A 11 Low beam light bulb 12V 55W 12 High beam light bulb 12V 55W 13 High beam lamp warning light 12V 1 2W 14 Front side light bulb 12V 5W 15 Four dashboards illuminating bulbs 12V 1 2W 16 Taillight bulb 12V 5W 17 License plate bulb 12V 5W 18 Low beam fuse 7 5A Electrical system ELE SYS 62...

Page 63: ... 1 Magneto flywheel 2 Voltage regulator 3 Pick up 4 Main fusible 15A 5 Battery 12V 9Ah 6 Starter relay 7 Starter motor 8 Start up button 9 Front and rear brake light button 10 Brake light filament 12V 21W 11 Fuse 7 5 A 12 Key switch 13 electronic control unit Electrical system ELE SYS 63 ...

Page 64: ... switch 5 Engine oil pressure sensor 6 Low oil pressure warning light 12V 1 2W 7 Reserve fuel light 12V 1 2W 8 Fuel gauge 9 Fuel level sender 10 Fuse 7 5 A 11 Immobilizer aerial 12 Low engine oil pressure sensor 13 Immobiliser LED 14 Front and rear brake light button 15 Taillight bulb 12V 5W 16 Starter motor 17 Starter relay 18 Start up button Electrical system ELE SYS 64 ...

Page 65: ...ation Desc Quantity 1 electronic control unit 2 Indicators switch 3 4 Turn indicator bulbs 12V 10W 4 Turn signal warning light bulbs 12V 2W 5 Main fusible 15A 6 Battery 12V 9Ah 7 Horn 8 Fuse 7 5 A 9 Key switch 10 Horn button Electrical system ELE SYS 65 ...

Page 66: ...igh beam warning light 3 Left turn indicator 4 Engine oil warning light 5 PIN CONNECTOR Specification Desc Quantity 1 Instrument panel lighting and headlamp warning light 2 Right turn indicator 3 Low fuel warning light 4 permanent power supply 5 Fuel gauge Checks and inspections Electrical system ELE SYS 66 ...

Page 67: ... hours so as not to affect the battery charge When the ignition switch is set to ON the theft deterring blinker function is deactivated Subse quently a flash confirms the switching to ON The duration of the flash depends on the electronic control unit program see figure Whenever the LED is off and remains so even when switching it to ON it is necessary to check if the battery is charged 15A main f...

Page 68: ...ed but it will run limited to 2000 rpm When trying to accelerate some evi dent loss of power may be felt Program the system with the MASTER Brown and SERVICE Blue keys as follows Insert the MASTER key turn it to ON and keep it in that position for 2 seconds limit values 1 3 seconds Alternatively insert all the available black keys and turn each one of them to ON for 2 seconds Insert the MASTER key...

Page 69: ...he LED is off for 2 seconds and then di agnosis codes are transmitted with 0 5 sec flash es After the failure code indication a steadily on LED signals that ignition is disabled see the table 2 FLASH CODE Example with programmed electronic control unit no transponder and or aerial malfunction Ignition disabled Vehicle immobilised 3 FLASH CODE Example with programmed electronic control unit aerial ...

Page 70: ...immobilizer system is efficient when after switching over to ON only a 0 7 sec flash is detected see diagram In this case the engine can be started Example with programmed control unit trans ponder programmed key and working aerial The ignition is enabled regular use conditions Ignition circuit All the control operations of the system that entail disconnecting cables to check connections and the d...

Page 71: ...tion Detach the connector from the ECU and check for continuity between terminals 3 purple and 8 black see figure If unacceptable values are found repeat the in spection directly from the positive and negative terminals of the H T coil primary circuit If the values are within the prescribed limit pro ceed by repairing the wiring or reattaching all wir ings otherwise replace the H T coil Electric c...

Page 72: ...ick Up N B THE MULTIMETER MUST BE SELECTED TO DETECT CONTINUOUS VOLTAGE Electric characteristic Pick Up voltage value Pick Up voltage value 2 Volt H V coil With the control unit and HV coil connected to the circuit measure the voltage of the coil primary dur ing the start up test with the voltage peak adaptor and connect the positive terminal to the earth one and the negative to the coil positive ...

Page 73: ...nerated power and idle stability For this reason it is very important that the idle speed is adjusted as prescribed Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Stator check Disconnect the connector from the voltage regu lator and check there is continuity between any yellow cable and the other two cables Electric characteristic Ohm value 0 7 0 9 Ohm Also check ...

Page 74: ...ff wait for the voltage to set at about 12 V Start the engine and measure the current gen erated by the system with lights on and a high running engine In case the generated current value is lower than 8A repeat the test using a new regulator and sta tor alternatively Choke Inspection Refer to the engine section to check the resistance and operating conditions of the component As re gards voltage ...

Page 75: ...e device and the ECU Turn signals system check If the turn signal lights are faulty proceed as fol lows Detach the ECU connector and check for battery tension between terminal 5 Orange and earth with the key switch onto ON Check the same is present between terminals 5 Orange and 8 Black If no tension is measured check the wiring other wise proceed as follows Jumper terminals 1 Black Blue and 5 Ora...

Page 76: ...charge mode Constant voltage charge equal to 14 40 14 70V Initial charge voltage equal to 0 3 0 5 for Nominal capacity Charge time 10 to 12 h recommended Minimum 6 h Maximum 24 h 3 Constant current battery charge mode Charge current equal to 1 10 of the battery rated capacity Charge time Maximum 5 h Dry charge battery WARNING Battery electrolyte is toxic and it may cause serious burns It contains ...

Page 77: ...nce the charge is over level the acid by adding distilled water Close and clean carefully 5 Once the above operations have been per formed install the battery on the vehicle ensuring that it is wired up properly 1 Hold the vertical tube 2 Look at the level 3 The float must be freed WARNING ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO RE PLACE THE SHORT TUBE WITH CLOSED END...

Page 78: ...he clamp marked with the positive sign 3 Recharging the battery Remove the battery from the vehicle removing the negative clamp first Regular bench charging must be carried out with the specific battery charger single or multiple setting the battery charger selector to the type of battery to be recharged Connections to the power supply source must be implemented by connecting the corresponding pol...

Page 79: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 80: ...erference between its supporting bracket and the cooling cover Removal of the engine from the vehicle Remove the left side fairing Remove the helmet compartment door Remove the full muffler assembly Remove the 3 rear brake transmission fixing screws indicated in the photograph Remove the throttle control cable from the car burettor indicated in the photograph Engine from vehicle ENG VE 80 ...

Page 81: ...e pipe from the manifold as shown in the photograph Remove the flywheel wiring connector the earth terminal and the starter motor positive cable indi cated in the figure Remove the clamp retaining the starter wiring and the heater indicated in the figure Engine from vehicle ENG VE 81 ...

Page 82: ...eater connections Unscrew the engine pin swinging arm nut on the right hand side of the vehicle and slide off the pin on the left hand side Support the vehicle adequately with a jack and remove the shock absorber lower clamping The engine is now free See also Exhaust assy Removal Engine from vehicle ENG VE 82 ...

Page 83: ...INDEX OF TOPICS ENGINE ENG ...

Page 84: ...move the cap dipstick from the engine oil filling hole Remove the 10 screws and the earth cable fas tened under one of them Remove the transmission cover If this operation is performed directly on the vehicle it is necessary to remove the cooling air coupling and the three air filter housing retainers Specific tooling 020423Y driven pulley lock wrench CAUTION Maybe a first batch of vehicles featur...

Page 85: ...ifold as well as the filter Removing the driven pulley shaft bearing Remove the clip from the inside of the cover Use the specific tools to remove the bearing from the crankcase CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm Engine ENG 85 ...

Page 86: ...r handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide Removing the driven pulley Remove the spacer the clutch bell and the whole driven pulley unit N B THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED Inspecting the clutch drum Check that the clutch bell is not worn or damaged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value Ø 134 5 mm Clutch bel...

Page 87: ...he magnetic base measure the bell eccentricity Repeat the measurement in 3 positions Central internal external If faults are found replace the bell Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic support for dial gauge Characteristic clutch bell inspection Limit eccentricity Admissible limit eccentricity 0 15 mm Removing the clutch Prepare the locking tool ...

Page 88: ...TH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL Specific tooling 020444Y Tool for fitting removing the driven pulley clutch 020444Y009 46x55 Wrench Inspecting the clutch Check the thickness of the clutch mass friction material The masses must not show traces of lubricants otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EX HIBIT A CENTR...

Page 89: ...g using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as shown in the figure Remove the roller bearing using the specific ex tractor N B REST THE HALF PULLEY ON A WOOD SUR FACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DRIVEN PULLEY UPON RE MOVING IT Specific tooling 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020439Y 17 mm guide Engine ENG 89 ...

Page 90: ...bile half pulley bushing Characteristic Minimum admissible diameter Ø 41 08 mm Standard diameter Ø 41 035 mm Refitting the driven half pulley bearing Assemble a new roller case using the specific punch fit the bearing with the label facing outward and insert it completely up to the punch on the half pulley N B REST THE HALF PULLEY ON A WOOD SUR FACE TO AVOID DAMAGING THE THREADED RINGLET OF THE DR...

Page 91: ... on the ringlet with the appropriate protection sheath Make sure the pins and collar are not worn re assemble the pins and collar Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole This operation is necessary to avoid the presence of greas...

Page 92: ...ITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO PREVENT A VARIATION IN THE RE TURN SPRING LOAD Characteristic Minimum thickness permitted 1 mm Support the driven pulley spring compressor ap propriate tool with the control screw in vertical axis Arrange the tool with the medium length pins screwed in position C on the inside Introduce the adapter ring 11 with...

Page 93: ...belt accord ing to its direction of rotation Lock the driven pulley again using the specific tool Preload the clutch return spring with a traction rotation combined action and place the belt in the smaller diameter rolling position Remove the driven pulley belt unit from the tool N B DURING THE SPRING PRELOADING PHASE BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREAD ING N B ...

Page 94: ...km etc check that the rim bottom of the toothing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Check that the driving belt is not damaged Check the width of the belt BELT SIZE Specification Desc Quantity Minimum width 21 5 mm Standard width 22 5 0 2 mm Engine ENG 94 ...

Page 95: ...bled rollers Remove the return rollers plate with the relative guide pads Inspecting the rollers case Check that the internal bushing is not abnormally worn and measure inner diameter N B DO NOT LUBRICATE OR CLEAN THE BUSHING BUSHING ROLLER CONTAINER Specification Desc Quantity Maximum allowable diameter Ø 26 121 mm Standard diameter Ø 26 0 0 021 mm BUSH SLIDE PULLEY Specification Desc Quantity Mi...

Page 96: ...ernal lining fixed half pulley external lining drive and nut spread threadlock on the thread and screw the nut to the prescribed torque Avoid the half pulley rotation using a calliper spanner N B REPLACE THE NUT WITH A NEW ONE AT EV ERY REFIT Specific tooling 020368Y driving pulley lock wrench Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Lockin...

Page 97: ...nch and the torque wrench tools Replace the plastic cover Specific tooling 020423Y driven pulley lock wrench Locking torques N m Transmission cover screws 11 13 Driven pul ley shaft nut 54 60 End gear Removing the hub cover Empty the rear hub through the oil drainage tap located inside the hub cover Remove the brake shoe and relevant spring Remove the 7 flanged screws as shown in the figure Remove...

Page 98: ...tractor to remove the three 15 mm bearings 2 in the crankcase and 1 in the hub cover Specific tooling 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings Removing the wheel axle bearings Take out the clip on the outside of the gearbox cover Remove the bearing with the adequate tools ad equately supporting the hub cover as shown in the figure Specific tooling 02037...

Page 99: ...rewdriver working from inside the bearing and being careful not to damage the housing make it come out of the belt transmission side Remove the seeger ring shown in the figure With the sectional punch remove the driven pulley shaft bearing Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide See also Removing the driven pulley Inspecting the hub shaft Check the th...

Page 100: ...ning it with ball bearing in view from the inside of the hub cover using the adequate tools Specific tooling 020376Y Adaptor handle Refit the Seeger ring with the opening facing the bearing as shown in the figure and fit a new oil guard flush with the crankcase Refitting the wheel axle bearing Heat up the parts using the specific heat gun Specific tooling 020151Y Air heater 020150Y Air heater supp...

Page 101: ...x 55 mm Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the specific heat gun Specific tooling 020150Y Air heater support 020151Y Air heater The three 15 mm bearings must be fitted using the appropriate tools Refitting the hub bearings Insert the cover prepared in the crankcase taking care of inserting the gear of the ...

Page 102: ... the groove on the control lever Locking torques N m Locking torque 24 27 Flywheel cover Cooling hood Remove the housing acting on the 4 retaining screws CAUTION DURING REMOVAL SLIDE THE HOUSING CONNECTOR ON THE HOUSING Loosen the clamp and remove the carburettor from the manifold Remove the complete manifold acting on the 2 retainers as shown in the figure Remove the 2 self threading screws left ...

Page 103: ...terwards Cooling fan Refit the parts in reverse order of the removal operation Make sure that there are spacers with the two rear retainers of the housing The long spacers should be in a high position CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR Remove the cooling fan by acting on the three fixings indicated in the figure Removing the stator Remove the electric terminal of the mi...

Page 104: ... THE REF ERENCE PIN AS SHOWN IN THE DETAIL DRAWING Locking torques N m Stator screw 3 4 Flywheel and starting Removing the flywheel magneto Lock the rotation of the flywheel using the calliper spanner Remove the nut CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS Specific tooling 020565Y Flywheel lock calliper spanner Extract the flywheel with the ex...

Page 105: ...e Pick Up Different values result from deformations visible on the Pick Up support N B A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED Locking torques N m Flywheel nut 52 58 Refitting the starter motor Fit a new O ring on the starter and lubricate it Fit the starter on the crankcase locking the two screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRI ...

Page 106: ...he two fixings shown in the figure Remove the tensioner with its gasket Remove the internal hex screw and the counter weight shown in the figure Remove the camshaft command pulley and its washer Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner pad The chain tensioning pad must be removed from the transmission side As ...

Page 107: ...BLE POSITION SO AS TO AVOID THE INVERSION OF INLET WITH THE OUTLET Removing the cylinder head Remove the spark plug Remove the 2 side fixings shown in the figure Loosen the 4 head cylinder fastening nuts in two or three stages and in criss cross fashion Remove the head the two centring dowels and the gasket N B IN CASE OF NEED THE HEAD MAY BE RE MOVED WITH THE CAMSHAFT PINS ROCK ING LEVERS AND FIX...

Page 108: ...oling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Remove the oil seals with the appropriate tool Remove the lower spring supports Specific tooling 020431Y Valve oil seal extractor Removing the cylinder piston assy Remove the chain guide pad Remove the cylinder base gasket CAUTION TO AVOID DAMAGING THE PISTON SUP PORT IT WHILE REMOVING THE CYL...

Page 109: ...AMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER AL LOWED SHOWS SIGNS OF WEAR OR OVER HEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER Characteristic Rod small end check up Maximum diameter 15 030 mm Rod small end check up Standard diameter 15 0 015 0 025 mm Inspecting the wrist pin Check the outer diameter of the gudgeon pin Characteristic Standard pin d...

Page 110: ...DING TO THE AXIS OF THE PIS TON Using a bore meter measure the inner cylinder diameter at three different points according to the directions shown in the figure Check that the coupling surface with the head is not worn or misshapen Pistons and cylinders are classified into catego ries based on their diameter The coupling is car ried out in pairs A A B B C C D D Characteristic Maximum allowable run...

Page 111: ...that indicated in the table replace the piston STANDARD COUPLING CLEARANCE Name Description Dimensions Initials Quantity Top piston ring 0 025 0 070 Middle piston ring 0 015 0 060 oil scraper 0 015 0 060 MAXIMUM ADMITTED CLEARANCE AFTER USE Name Description Dimensions Initials Quantity Top piston ring 0 080 mm Middle piston ring 0 070 mm oil scraper 0 070 mm Removing the piston Install piston and ...

Page 112: ... ring gap and the word TOP towards the crown of the piston The tapered side of the middle piston ring should always be facing away from the crown of the pis ton Fit the middle piston ring with the identification letter facing the crown of the piston In any case the step must be facing opposite the piston top Fit the top piston ring with the word top or the reference mark facing the crown of the pi...

Page 113: ...k 020427Y Piston fitting band Inspecting the cylinder head Using a trued bar check that the cylinder head surface is not worn or distorted Check that the camshaft and rocking lever pin bearings show no signs of wear Check that the cylinder head cover surface the intake manifold and the exhaust manifold are not worn Characteristic Maximum admitted unevenness Head check 0 05 mm STANDARD DIAMETER Spe...

Page 114: ...t the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole assembly Inspecting the valve sealings Measure the width of the sealing surface on the valve seats VALVE SEAL SURFACE Specification Desc Quantity Inlet valve seal surface 2 4 2 8 mm Outlet valve seal surface 2 2 2 6 mm Inspecting the valve housings Remove any carbon forma...

Page 115: ...t V Characteristic Wear limits Max 1 6 mm Inspecting the valves Measure the diameter of the valve stems in the three positions indicated in the diagram Calculate the clearance between valve and valve guide Characteristic Minimum diameter admitted Inlet 4 96 mm Minimum diameter admitted Outlet 4 95 mm Standard clearance Inlet 0 013 0 040 mm Standard clearance Outlet 0 025 0 052 mm Maximum clearance...

Page 116: ...ly with a fine grained lapping compound During grinding keep the cylinder head in a horizontal position This will prevent the lapping compound residues from penetrating between the valve stem guide coupling CAUTION TO AVOID SCORING THE CONTACT SUR FACE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PROD UCT FOR THE TY...

Page 117: ...ngs one at a time Specific tooling 020306Y Punch for assembling valve seal rings Fit the valves the springs and the spring retaining caps Using the appropriate tool with adapter 11 compress the springs and insert the cotters in their seats Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft Inspect the cam sh...

Page 118: ...ial clearance admitted 0 42 mm Check there are no signs of wear on the auto matic valve lifter cam or the end of stroke roller or the rubber buffer on the automatic valve lifter retaining cover Check that the valve lifting spring has not yielded Replace any defective or worn components Check there are no signs of scoring or wear on the rocking lever bolt Check there are no signs of wear on the pad...

Page 119: ...ain side and tighten them to the specified torque N B BEFORE INSTALLING THE HEAD MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET Locking torques N m Locking torque 11 13 Fit the timing chain sprocket wheel on the crank shaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the tensioner pad by the cylinder head Fi...

Page 120: ...the reference 2V in corre spondence with the reference mark on the head Fit the pulley onto the camshaft Assemble the counterweight with the corre sponding fixing screw and tighten to the specified torque Locking torques N m Locking torque 7 8 5 Fit the end stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft Fit the automatic valve lifter return spri...

Page 121: ...er tightening it to the prescribed torque Locking torques N m Locking torque 5 6 Adjust the valve clearance Fit the spark plug Electric characteristic Recommended spark plug CHAMPION RG4HC Electrode gap 0 8 mm Locking torques N m Locking torque 12 14 Assemble the casing sealing gasket on the head On the fitting direction use the supplements on the timing side as reference Assemble the screw fixing...

Page 122: ...he transmission cover as described in the transmis sion chapter Locking torques N m Locking torque 11 13 Crankcase crankshaft Precautionary remove the following units transmission cover driving pulley driven pulley and belt rear hub cover gears bearings and oil seals as described in the transmission chapter Remove the oil sump the by pass the chain compartment cover and the oil pump as in the lu b...

Page 123: ... screws to the crankcase Separate the crankcase while keeping the crank shaft in one of the two halves of the crankcase Remove the crankshaft CAUTION IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT ACCIDENTALLY FALL Remove the coupling gasket of the crankcase halves Remove the two screws and the internal cover shown in the diagram CAUTION WHILE OPENING THE CRANKCASES AND RE MOVING THE DRIVING SHAFT CH...

Page 124: ...between these surfaces as shown in the diagram CAUTION BE CAREFUL NOT TO LET THE MEASURE MENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard clearance 0 036 0 054 mm If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have any defect the problem must be due to either excessive wear or wrong machining on the crankcase CAUTION ...

Page 125: ...alignment in the 4 points indicated in figure Check that the driving shaft cone the tab seat the oil seal capacity the toothed gear and the threaded tangs are in good working order In case of failures replace the crankshaft The connecting rod head bushings cannot be re placed For the same reason the connecting rod may not be replaced and when cleaning the crankshaft be very careful that no impurit...

Page 126: ...aning the housing and oil ducts for the following components the oil pump the oil by pass valve the main bushings and the cooling jet on the transmission side see diagram Take particular care also that there are no signs wear in the oil by pass valve housing see Chapter Lubrication as this could prevent a good seal in the valve which regulates the oil pressure N B THE JET IS FED THROUGH THE MAIN B...

Page 127: ...BUSHING AND CONNECTING ROD LUBRICA TION PRESSURE Inspect the mating surfaces on the crankcase halves for scratches or deformation taking partic ular with the surfaces that mate with the cylinder and the mating surfaces between the crankcase halves Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in the oil pressure and affect the lubricating pres su...

Page 128: ...hings driving depth compared with the crankshaft axial clearance of the limiting surface N B TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES Characteristic Standard driving depth 1 35 1 6 Check the inside diameter of the main bushings in the three directions indicated in the diagram Repeat the measurements for...

Page 129: ... a new gasket on one of the crankcase halves preferably on the transmission side to gether with the locating dowels Locking torques N m Locking torque 27 33 Lubricate the main bushings and insert the crank shaft in the transmission side crankcase half Reassemble the two crankcase halves Fit the 11 screws and tighten them to the pre scribed torque N B WHEN FITTING THE HALF CASING AND THE CRANKSHAFT...

Page 130: ...its corre sponding cover to the specific torque N B REMOVE ANY EXCESS FROM THE CRANK CASE COUPLING GASKET ON THE CYLINDER PLANE TO ENSURE BETTER SEALING PER FORMANCE N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING Specific tooling 020425Y Punch for flywheel side oil seal Locking torques N m Locking torque 24 30 Lubricati...

Page 131: ...Conceptual diagrams Engine ENG 131 ...

Page 132: ... between 3 2 4 2 atm Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the prescribed torque and fit the fan cover If the oil pressure is outside the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT ...

Page 133: ... Screw the threaded bar onto the base of the tool and extract the oil guard Specific tooling 020622Y Transmission side oil guard punch Refitting Prepare the new oil guard lubricating the sealing lip Warning do not lubricate the surface for keying onto the engine crankcase CAUTION DO NOT LUBRICATE THE SURFACE FOR KEY ING ONTO THE ENGINE CRANKCASE Engine ENG 133 ...

Page 134: ...ankcase CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL GUARD FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL GUARD SHEATH Orientate the oil guard by inserting the bracket which is part of the specific tool Tighten the threaded bar onto the crankshaft as far as it will go Engine ENG...

Page 135: ...IN Assemble a new oil seal on the flywheel side using the specific tool as shown in the photograph N B FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING Specific tooling 020425Y Punch for flywheel side oil seal Oil pump Removal Remove the cover of the pump control pulley us ing the two retainers as shown in the figure Block th...

Page 136: ...RE THAT THE INITIAL DIREC TION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the clip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Reassemble the rotors in the pump body keep ing the two reference marks visible Replace the clip Using a thickness gauge check the distance be tween the rotors in the posi...

Page 137: ...il pump shaft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the assembly Fit the pulley to the pump the central screw to the specified torque and the belleville washer Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE BELLEVILLE WASHER SO THAT ITS OUTE...

Page 138: ...d in the figure and the 2 rear brake transmission fixing brackets Remove the spring the by pass piston and the gasket shown in the second image Inspecting the by pass valve Check the unloaded spring length Check that the small piston is not scored Ensure that it slides freely on the crankcase and that it guarantees a good seal If not eliminate any impurities or replace defec tive parts Characteris...

Page 139: ...ng the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the crankshaft and con necting rod Locking torques N m Locking torque 11 13 Fuel supply Disconnect the fuel supply and the suction taking pipe from the carburettor Check that there are no fuel leaks between the two tubes Close the fuel outlet pipe By means of the MITIVAC pump apply 0 1 bar of suction ...

Page 140: ...livery tube and the suction tube Loosen the clip and remove the tap Clean the tank and the filter of the tap with a spe cific solvent Refit the tap making sure that there is an O Ring Turn the tap to the direction it had before it was removed and block the clip N B THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING Removing the carburettor To detach the carburettor from the engine it...

Page 141: ...nd the starter support with the gasket Remove the clamp and cover with the airing filter of the diaphragm chamber Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING THE REMOVAL OF THE CARBURET TOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Engine ENG 141 ...

Page 142: ...ove the vacuum valve together with the di aphragm Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Remove the 4 screws indicated in the figure Engine ENG 142 ...

Page 143: ...mp from the tank N B CAUTION THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES SPRING AND BALL N B AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle Engine ENG 143 ...

Page 144: ... Remove the maximum nozzle Remove diffuser Engine ENG 144 ...

Page 145: ...Remove the minimum flow set screw and the spring CAUTION DO NOT ATTEMPT REMOVING PARTS EM BEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PLUNGER HOUSING STARTER NOZZLE PIT COVER FOR PRO GRESSIONS AND INLET NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNECTION SCREWS THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES T...

Page 146: ...uging outlet section controlled by flow screw progression holes near the throttle valve For the starter circuit blow the connection pipe properly with the jet This is necessary because the nozzle support hides other inaccessible internal calibrations Blow the intake nozzle properly N B THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE NOZZLE INCORRECT ORIENTAT...

Page 147: ...blow the minimum nozzle properly and reassemble it Properly wash and blow the components of the sprayer maximum circuit the diffuser and the noz zle Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser Assemble the diffuser making sure the sprayer is being adequately inserted and lock it Assemble the maximum nozzle Check that the tapered pin doe...

Page 148: ...tion pump valves fol lowing this order INTAKE VALVE A Spring Ball Nozzle IN VALVE M Ball Spring Nozzle N B THE IN VALVE NOZZLE CORRESPONDING TO THE ACCELERATION PUMP IS MILLED Check the screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is free to rotate in ...

Page 149: ...d be determined by an exhaust fume analysis Adjust the carburettor by turning the screw twice from the close position Level check Place the carburettor inclined as shown in the figure Check that the float reference is parallel to the tank coupling surface If different positions are detected change the plunger control metal plate direction to obtain the position described above Engine ENG 149 ...

Page 150: ...ubber pipe to the bleeding intake of the fuel tank Keep the pipe up so that the ends are higher than the venturi pipe Unscrew the bleed screw and stabilise the petrol level then measure as shown in the dia gram Engine ENG 150 ...

Page 151: ...d or has hardened otherwise replacement the whole valve Insert the tapered pin into the vacuum valve housing Reassemble the vacuum valve on the carburettor body taking care that the tapered pin is inserted into the sprayer N B THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION Reassemble the spring with the pin lock Remove the cover of the vacuum chamber being careful to correctly insert the ...

Page 152: ...y the filter sponge of the am bient pressure intake Reassemble the filter with its clamp Wash and blow dry the starter support Assemble a new gasket on the carburettor body and tighten the 2 fixing screws Engine ENG 152 ...

Page 153: ... resistance when adjusted to the ambient temperature With a 12V battery power the automatic starter and check that the piston protrudes as much as possi ble The correct warm up time depends on the ambi ent temperature If protrusion resistance or timing values are dif ferent from the ones prescribed replace the start er Assemble the starter to the carburettor being careful to position the O Ring co...

Page 154: ...cellent conditions air filter clean and sealed exhaust system completely sealed Warm up the engine for at least 5 minutes at around 50 Km h Connect the vehicle to an exhaust analyser in serting the analyser probe into a extension hose fitted airtight to the outlet of the silencer Connect the thermometer of the multimeter 020331y to the sump using the oil cap specifi cally made for insertion of the...

Page 155: ...of a non airtight condition on the exhaust system Unburnt hydrocarbons HC are measured in parts per million PPM the value of the HC de creases with increased rpm with the engine idling it is normal to measure 200 â 400 PPM these exhaust values are considered normal for an engine with motorcycle distribution diagram Much higher values can be caused by engine misfiring due to a too thin mixture low ...

Page 156: ... B THE WASTED SPARK IGNITION SYSTEM OF FERS REMARKABLE POWER READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED CORRECT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 8000 Characteristic Idle adjustment Pipe sizes Ø 40 mm Idle adjustment length 500 600 mm Engine ENG 156 ...

Page 157: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 158: ...aul Cuscinetti a sfere sul mozzo ruota Remove the front wheel Keep the wheel level by means of two wooden wedges With the appropriate pliers and tool remove the wheel bearing on the side the rpm indicator detects movement as shown in the photograph Remove the internal spacer Use appropriate handle adaptor and guide and hit with a mallet to extract the bearing and the spacer bushing on the brake di...

Page 159: ...h the centring ring facing to the brake disk side as shown in the photo Use an appropriate tool to insert the bearing on the rpm indicator movement detector side Specific tooling 001467Y009 Driver for OD 42 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings 020357Y 32 x 35 mm adaptor 020376Y Adaptor handle 020412Y 15 mm guide 020456Y Ø 24 mm adaptor Refitting the front wheel Follow the same...

Page 160: ...R FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting Carry out the operations in the reverse order to the removal observing the prescribed tightening tor que Locking torques N m Handlebar fixing screw 50 55 Front fork Overhaul Replacement of seal ring rod disassembly Remove the wheel axle Remove the lower screw 1 Discharge the oil in the suspension Remove the stem Replace the sealing rings 3...

Page 161: ...teering bearing tracks with the recommended grease Tighten the lower ring nut A and the upper ring nut B to the specified torque Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m Steering lower ring nut 8 10 ...

Page 162: ...s from the chassis use the appropriate tool as shown in the figure N B To remove the lower seating of the lower bearing just use a screwdriver as a lever between the seat ing and the shell LOWER AND UPPER SEATING FROM THE CHASSIS Titolo Durata Valore Testo Breve 4000 car Indirizzo Immagine Lower and upper seat ing from the chassis Washer and upper bearing upper seat After removing the upper seatin...

Page 163: ...the specified torque WARNING FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN ORDER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE Locking torques N m Rear wheel axle 104 126 Shock absorbers Removal To replace the shock absorber remove the bat tery access flap to reach and remove the shock absorber frame anchoring nut Then remove the shock absorber engine anchorage nut When refitting tighten the...

Page 164: ...N m Shock absorber frame nut torque 20 to 25 Nm Centre stand Complete centre stand replacement Undo the screw marked in the figure When refitting secure to the prescribed torque Locking torques N m Centre stand screw 32 40 Suspensions SUSP 164 ...

Page 165: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 166: ...ed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons 6 5 Check that the plates and the body are whole and in good condition that the cylinder and the floating body of the cal liper do not show signs of scratches or erosion otherwise replace the e...

Page 167: ...pads The body and the reaction plate body work inte grally and can move axially with respect of the fixed plate that is integral to the strut The pistons forced by pressure to push the pad to the disk cause the reaction plate to push in turn the other pad towards the disc The brake pad lock spring 1 Pad fixing screws 2 Reaction plate fixing screws 3 Reaction plate 4 Fixed plate 5 Floating body 6 P...

Page 168: ...ghtening screw 24 27 Brake fluid tube calliper fitting 19 24 See also Front Front brake disc Removal Remove the front wheel undoing the axle clamp ing Undo the five disc clamps Locking torques N m Disc tightening screw 8 10 Refitting When refitting position the disc correctly making sure that it rotates in the right direction Locking torques N m Disc tightening screw 8 12 Braking system BRAK SYS 1...

Page 169: ... pads Remove the pads being careful of the pads spring clamp Check the thickness of the pads Characteristic Minimum value 1 5 mm See also Front brake calliper Refitting To fit proceed as follows Insert the two pads in the callipers Screw the two pad lock pins to the correct torque and apply the recommended product Fit the calliper on its support tightening the two screws to the prescribed torque N...

Page 170: ... the operation is over tighten up the oil bleed screw to the prescribed torque N B IF AIR CONTINUES TO COME OUT DURING PURGING EXAMINE ALL THE FITTINGS IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS CAUTION DURING THE OPERATIONS THE VEHICLE MUST BE ON THE STAND AND LEVEL N B DURING PURGING FREQUENTLY CHECK THE LEVE...

Page 171: ... BE OIL ON IT Specific tooling 020329Y MityVac vacuum operated pump Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Locking torques N m Oil bleed screw 7 10 Front brake pump After removing the front and rear handlebar covers act on the two stand fixing points see the figure Disconnect the tube collecting the brake oil in a container On refitting perform the operation in r...

Page 172: ...SC WITH A HIGH QUALITY SOL VENT CONTACT WITH BRAKE FLUID WILL DAMAGE PAINTED SURFACES RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLOTH THE SEALING RINGS MUST BE IMMERSED IN THE OPERATING LIQUID Refitting Before fitting the parts must be perfectly clean and free of traces of oil diesel fue...

Page 173: ...wheel have been re moved follow these steps 1 Remove the shoe spring using the specific span ner 2 Remove the shoe with the aid of a lever 3 Refit the new shoes giving a few taps with the mallet 4 Attach the spring using the specific pliers Specific tooling 020325Y Brake shoe spring calliper Braking system BRAK SYS 173 ...

Page 174: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 175: ...e key switch Make a hole on the block using a drill as shown in the figure Insert the wheel cylinder with the key and with the anchoring tab facing down halfway on the lock body taking care that the insertion phase of the key is oriented matching ON the only position that enables the cylinder to get into the lock body now turn the key leftwards to OFF and at the same time press until the cylinder ...

Page 176: ...h the filter sponge To disassemble the filter housing unscrew the 2 bottom screws and disconnect the manifold con nections the carburettor and the external air in take Rear mudguard Remove the side fairings Remove the 4 screws shown in the photograph Chassis CHAS 176 ...

Page 177: ... by undoing the 4 screws indicated in the figure Fuel tank Remove the side fairings Remove the rear mudguard Remove the crews shown in the photograph Remove the shock absorber upper clamping in order to create the necessary space to take out the tank Chassis CHAS 177 ...

Page 178: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 179: ...arm pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam low beam position and parking lights and the respective warning lights Adjusting the headlights according to the regulations currently in force Tail light parking light stop light Front and rear stop light switches Turn indicators and their warnin...

Page 180: ...UT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION THE BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP ...

Page 181: ...ION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the frame and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirror...

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