Derbi BOULEVARD 50 2T Workshop Manual Download Page 59 | Manualshive

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Removal of the engine from the vehicle

Remove the engine from the frame

-Disconnect the battery.
-Remove the muffler assembly.
- Remove the rear wheel.
- Remove the mechanical transmission of the rear brake.
-Disconnect the electric terminals.
- Remove the throttle grip and mixer transmissions.
- Disconnect the hoses (petrol-oil-vacuum-operated cock control).

WARNING

Be very careful when handling fuel.

CAUTION

When installing the battery, first attach the positive cable and then the negative cable.

WARNING

Wear safety goggles when using hitting tools.

Engine from vehicle

ENG VE - 59

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Summary of Contents for BOULEVARD 50 2T

Page 1: ...WORKSHOP MANUAL BOULEVARD 50 2T ...

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Page 5: ...ARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

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

Page 7: ...t 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 spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing ri...

Page 8: ... Desc Quantity Frame prefix ZAPM44100 1001 VTHBR1A1 xxxxxxxxx Engine prefix Dimensions and mass DIMENSIONS AND MASS Specification Desc Quantity Dry weight 97 Kg Length 1 880 Maximum height 1150 mm Seat height 785 Width 735 Wheelbase 1 340 Characteristics CHAR 8 ...

Page 9: ...Sponge soaked in a mixture 50 SELENIA Air Filter Oil and 50 unleaded petrol Starting system electric starter kick starter Lubrication With blend and variable oil variable according to the engine revolutions and the throttle valve opening by means of a pump controlled by the driving shaft with toothed belt Fuel supply Gravity feed with unleaded petrol with a minimum octane rat ing of 95 with carbur...

Page 10: ...plug CHAMPION RN2C Battery 12V 4Ah Main fuse 7 5 A Generator In alternate current with three output sections Frame and suspensions FRAME AND SUSPENSIONS Specification Desc Quantity Type of chassis Welded tubular steel chassis with stamped sheet reinforce ments Front suspension Telescopic mechanical fork 76mm travel Rear suspension Single hydraulic shock absorber 72 5 mm travel Brakes FRENI Specifi...

Page 11: ...air and refit to place Refit the intake cap respecting the angle reference 3 Undo the two fixing screws 2 on the aluminium cover of the secondary air housing in order to reach the polyurethane sponge inside that hous ing clean as indicated in point 2 and refit all elements after checking the steel tab is not de formed and or does not guarantee correct tight ness at its fitting replace if necessary...

Page 12: ... Disc tightening screw 8 10 Oil bleed screw 7 10 FRONT SUSPENSION Name Torque in Nm Lower fork fixing screw 15 20 Front wheel axle nut 45 50 STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut 35 40 Steering lower ring nut 8 10 Handlebar fixing screw 50 55 ENGINE ASSEMBLY Name Torque in Nm Clutch bell nut 40 44 Clutch lock ring nut 55 60 Nut locking driving pulley on crankshaft 40 44 Nm St...

Page 13: ... PISTON AND CYLINDER Name Initials Cylinder Piston Play on fitting Standard coupling M 40 005 40 012 39 943 39 95 0 055 0 069 Standard coupling N 40 012 40 019 39 95 39 957 0 055 0 069 Standard coupling O 40 019 40 026 39 957 39 964 0 055 0 069 Standard coupling P 40 026 40 033 39 964 39 971 0 055 0 069 coupling 1st oversize M1 40 205 40 212 40 143 40 15 0 055 0 069 coupling 1st oversize N1 40 212...

Page 14: ...Connecting rod 11 750 0 05 A clearance E 0 25 to 0 50 shoulder washer 0 5 0 03 G clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Half shaft transmission side 13 75 0 040 C clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Flywheel side half shaft 13 75 0 040 D clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 Lining between the shoulders 40 64 H clearance E 0 25 to 0 50 clearance F 0 20 to 0 75 ...

Page 15: ... oil synthetic oil for 2 stroke engines JASO FC ISO L EGD AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid MONTBLANC MOLYBDENUM GREASE Grease for driven pulley shaft adjusting ring and movable driven pulley housing Grease with Molybdenum disulphide AGIP GREASE PV2 Grease for steering bearings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature...

Page 16: ...INDEX OF TOPICS TOOLING TOOL ...

Page 17: ...tting steering seats 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings Tooling TOOL 17 ...

Page 18: ...21 Extraction pliers for ø 11 mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer ing tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater mounting Tooling TOOL 18 ...

Page 19: ...code Description 020151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020165Y Start up crown lock 020166Y Pin lock fitting tool Tooling TOOL 19 ...

Page 20: ...20261Y Starter spring fitting 020262Y Crankcase splitting plate 020265Y Bearing fitting base 020325Y Pliers for brake shoe springs 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing Tooling TOOL 20 ...

Page 21: ...Stores code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger Tooling TOOL 21 ...

Page 22: ...code Description 020335Y Magnetic mounting for dial gauge 020350Y Electrical system check instrument 020357Y 32x35 mm Adaptor 020359Y 42x47 mm Adaptor 020376Y Adaptor handle 020412Y 15 mm guide Tooling TOOL 22 ...

Page 23: ...Stores code Description 020456Y Ø 24 mm adaptor 020483Y 30 mm guide 020565Y Flywheel lock calliper spanner 494929Y Exhaust fumes analyser Tooling TOOL 23 ...

Page 24: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 25: ...wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AFTER 10000 KM 50000 KM 95 Action Hub oil change Spark plug electrode gap replacement Air filter clean Idling speed adjustment Oil mixer throttle linkage adjustment Variable speed rollers replacement Odometer gear greasing Driving belt checking Steering adjustment Brake co...

Page 26: ...tment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Vehicle and brake test road test See section Adjusting the idle speed AFTER 30000 KM 130 Action Hub oil change Spark plug electrode gap replacement...

Page 27: ...em and battery check Headlight adjustment Tyre pressure and wear check SAS box sponge cleaning Vehicle and brake test road test See regulations in the Adjusting the idle speed section See regulations in the Secondary air system section Carburettor Disassemble the carburettor in its parts wash all of them with solvent dry all body grooves with compressed air to ensure adequate cleaning Check carefu...

Page 28: ...T THE CHECKS PROVIDED FOR IN THE ELECTRICAL SYSTEM CHAPTER CAUTION BEFORE CARRYING OUT THE ABOVE CHECKS CHECK THE CORRECT KEYING OF THE FLYWHEEL ON THE CRANKSHAFT Specific tooling 020330Y Stroboscopic light to check timing Spark plug Place the vehicle on its central stand Remove the central cover indicated in the figure by undoing the 2 fixing screws Disconnect spark plug HV wire hood Undo the spa...

Page 29: ...nded spark plug CHAMPION RN2C Electric characteristic Electrode gap 0 6 to 0 7 mm Locking torques N m Spark plug 25 30 Nm Hub oil Check Do the following to check the correct level 1 Stand the vehicle on the centre stand on flat ground 2 Remove the dipstick A and dry it with a clean cloth Reinsert it screwing it in all the way 3 Remove the stick and check that the oil level is slightly over the sec...

Page 30: ... water and neutral soap Dry with a clean cloth and short blasts of com pressed air Saturate with a 50 mixture of gasoline and oil Drip dry the filter and then squeeze it between the hands without wringing Let it dry and refit it again CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER Recommended products AGIP FILTER OIL Oil for ai...

Page 31: ...d up with the reference mark on the mixer body as shown in the figure While doing this the engine must be fuelled with a 2 oil mixture 0 5 litre minimum if the reservoir is empty CAUTION IN CASE OF DISMANTLING OR RUNNING OUT OF OIL IN THE RESERVOIR BLEED THE MIXER AS FOLLOWS RE FILL THE OIL RESERVOIR WHEN THE MIXER IS FITTED TO THE VEHICLE AND THE ENGINE IS OFF UNDO THE MIXER PIPE FROM THE CARBURE...

Page 32: ...SE OF ACCIDENTAL CONTACT WASH WITH WATER CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK CAUTION THE BRAKE FLUID IS HYGROSCOPIC IN OTHER WORDS IT ABSORBS MOISTURE FROM THE SURROUNDING AIR IF THE CONTENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEF FICIENT NEVER USE BRAKE LIQUID IN OPEN OR PARTIALLY U...

Page 33: ...with screw A N B THE ABOVE PROCEDURE COMPLIES WITH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED CO check In the event that the exhaust on the vehicle being tested does not have an exhaust gases collection port proceed as follows Remove the R H side fairing Remove the secondary ai...

Page 34: ...ith the air filter clean and the spark plug in good condi tions Remove the R H side fairing Warn up the engine by riding the vehicle on the road for at least 10 minutes Shut down the engine Remove the 2 secondary air box screws shown in the figure Place a plastic sheet between the one way valve and the aluminium outlet as shown in the figure Ensure the one way valve packing properly seals the alum...

Page 35: ...ilters inspection and cleaning After removing the spark plug cap remove the RHS fairing by loosening the three fixing screws B shown in the figure Remove the SAS aluminium cover fixing screws A Detach the metal hose from its rubber hous ing on the cover without detaching it from the cover bellow Hence remove plate and plastic cov er extract the sponge and wash it with soap Dry with compressed air ...

Page 36: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 37: ...nce of oil Dirt Check the cap with filter is fitted to the transmission cover clean the speed variator replace the rollers if worn out Rear wheel spins at idle REAR WHEEL Possible Cause Operation Idling rpm too high Check the idling speed and if necessary adjust the C O Clutch fault Check the spring friction mass and the clutch bell Air filter housing not sealed Correctly refit the filter housing ...

Page 38: ...essed air Water in the carburettor Empty the tank through the appropriate bleed nipple Air filter dirty Clean or replace Defective floating valve Check the proper sliding of the float and the functioning of the valve Tank breather hole obstructed Restore the proper reservoir aeration Engine tends to cut off at idle ENGINE STOP IDLING Possible Cause Operation Minimum nozzle dirty Wash the nozzle wi...

Page 39: ...erate the engine without the clutch bell Check the cap with filter is fitted to the transmission cover Insufficient braking BRAKING SYSTEM MALFUNCTION Possible Cause Operation Poor braking The rear drum type brake is adjusted by regulating the special adjustment on the wheel bearing in mind that with the control levers in the rest position the wheels must turn freely The braking action should begi...

Page 40: ...he red wire is connected to the terminal marked Follow the instructions in the ELECTRICAL SYSTEM chapter for the recharging of the batteries Steering and suspensions Rear wheel REAR WHEEL Possible Cause Operation Idle speed set too high Adjust idle speed Adjust C O if necessary Faulty clutch Check springs frictional weights and clutch housing Heavy steering STEERING HARDENING Possible Cause Operat...

Page 41: ...he condition of the ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushings Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Oil leakage from suspension Service the pumping members and check the sleeves and sealing rings are in good conditions Replace the damaged parts Troubleshooting TROUBL 41 ...

Page 42: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 43: ...rake 2 Light switch 3 Turn indicator switch 4 Horn button 5 Horn 6 Front turn indicator bulbs Front turn indicator bulbs 12V 10W x 2 7 Front left turn indicator 8 Heater control device 9 Magneto flywheel 10 Electronic ignition device 11 Starter motor Electrical system ELE SYS 43 ...

Page 44: ...t right turn indicator 29 Key switch 30 Starter button 31 Front brake stop button 32 Headlight 33 Headlight bulb 12V 35 35W 34 Front tail light bulb Type All glass Power 12V 5W Quantity 1 35 Left turn indicator warning light 12V 2W 36 Headlight warning light 12V 1 2W 37 High beam warning light 12V 1 2W 38 Instrument panel light bulbs Type All glass Power 12V 1 2W Quantity 3 39 Low fuel warning lig...

Page 45: ...Ignition IGNITION Specification Desc Quantity 1 Electronic control unit 2 Magneto flywheel 3 Pick up 4 Key switch 5 Spark plug Electrical system ELE SYS 45 ...

Page 46: ...ar light bulb 12V 5W 5 Headlight bulb 12V 35 35W 6 High beam warning light 12V 1 2W 7 N 3 instrument lighting bulbs 12V 1 2W 8 Taillight bulb 12V 5W 9 Headlight warning light 12V 1 2W 10 Heater control device 11 Key switch contacts 12 Fuse 7 5A 13 Carburettor heater 14 Automatic starter 15 Battery 12V 4Ah Electrical system ELE SYS 46 ...

Page 47: ...NG Specification Desc Quantity 1 Magneto flywheel 2 Voltage regulator 3 Main fuse 7 5A 4 Brake light filament 12V 21W 5 Front and rear brake light button 6 Start up button 7 Starter motor 8 Remote starter switch 9 Battery 12V 4Ah Electrical system ELE SYS 47 ...

Page 48: ...ltage regulator 3 Key switch 4 Main fuse 7 5A 5 Brake light filament 12V 21W 6 Front and rear brake light button 7 Start up button 8 Starter motor 9 Remote starter switch 10 Battery 12V 4Ah 11 Low oil warning light 12V 1 2W 12 Oil level sender 13 Low fuel warning light 12V 1 2W 14 Fuel gauge 15 Fuel level sender Electrical system ELE SYS 48 ...

Page 49: ...nd inspections 1 No load test the starter motor when unloaded must absorb no more than 10A with a supply volt age 12V and must rotate at 15 000 rpm 2 Load test when the starter motor is so braked that it absorbs 47A with supply voltage 10V tor que of 0 2 N m must be obtained at 10 000 rpm 3 Static torque test when the rotor is locked and the supply voltage is 7V the absorbed current must not excee...

Page 50: ... the control unit If after replacement the vehicle starts properly the control unit is failing and must be replaced If the failure persists check the generator and the stator components as follows After visually checking the electrical connections use a specific tester to measurement the stator winding and the pickup see table If any failure is found after checking the loading coil and the pick up...

Page 51: ... tester 020331Y If the continuity checks or the inspections on the coil and pick up are incorrect proceed by replac ing the stator otherwise replace the ECU Remember to detach the ECU wirings when the engine is not running Specific tooling 020331Y Digital multimeter PICK UP CHECK FIGURE A Specification Desc Quantity 1 Red cable 1 and White cable 2 90 140 Ohm RECHARGING COIL CHECK FIGURE B Specific...

Page 52: ...ault in the voltage regulator can cause the fol lowing problems depending on the type of fault 1 Blow out of the lighting system bulbs 2 Failure of the lighting system 3 Excessive battery charging blowing of main fuse 4 Battery recharging failure 5 Failure of the turn indicators 6 Failure of the oil and petrol check lamp Operations FAULT 1 Make sure that at 5000 rpm with the lights on that the reg...

Page 53: ...ached replace the reg ulator because it is certainly inefficient and re place the protection fuse Following the replacement measure the current and the recharging voltage on the battery ends FIG B The values detected must be 1 5 2 A and 13 V at 3000 rpm FAULT 4 a By positioning tester 020331Y between the yel low wire terminal 8 on the regulator and the black wire 6 FIG D check the generator output...

Page 54: ...y FIG F Repeat the procedure now placing the tester probes between contacts 5 yellow red and 6 black and check the presence of the battery voltage with the key switch set to ON If there is no voltage check the regulator ground wiring FIG G If the above tests have positive results jump the contacts 5 yellow red and 7 blue black on the connector set the key switch to ON and shift the turn indicator ...

Page 55: ...FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1 Voltage check Before installing the battery on the vehicle check the open circuit voltage with a normal tester If the voltage exceeds 12 60 V the battery may be installed without any renewal recharge If voltage is below 12 60 V a renewal recharge is required as explained in 2 2 Constant voltage battery charge mode Constant voltage equal to 14 40...

Page 56: ... of less than 20 Bé indicates that the battery is completely flat and it must therefore be recharged After charging the battery check each element electrolyte level and density If the scooter is not used for a given time 1 month or more it will be necessary to periodically recharge the battery The battery runs down completely in the course of three months If it is necessary to refit the battery in...

Page 57: ...ndoors Always protect your eyes when working close to batteries Keep out of the reach of children 1 Remove the short closed tube and the caps then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1 26 corresponding to 30 Bé at a minimum temperature of 15 C until the upper level is reached 2 Leave to rest for at least 2 hours then restore the leve...

Page 58: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 59: ...f the rear brake Disconnect the electric terminals Remove the throttle grip and mixer transmissions Disconnect the hoses petrol oil vacuum operated cock control WARNING Be very careful when handling fuel CAUTION When installing the battery first attach the positive cable and then the negative cable WARNING Wear safety goggles when using hitting tools Engine from vehicle ENG VE 59 ...

Page 60: ...INDEX OF TOPICS ENGINE ENG ...

Page 61: ...lies to it by means of the spring to do this it is necessary to rotate the toothed sector slightly see the figure CAUTION WHILE REMOVING THE TOOTHED SECTOR BE VERY CAREFUL OF THE SPRING TENSION IT COULD CONSTI TUTE A HAZARD FOR THE OPERATOR Upon refitting apply the recommended grease to the bushing to the spring and along the toothed sector Use the special tool for the charging of the spring as sh...

Page 62: ...ide to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing N B IN CASE OF DIFFICULTY A STANDARD 8MM INSIDE DI AMETER EXTRACTOR CAN BE USED Refitting the driven pulley shaft bearing Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the ins...

Page 63: ... that the clutch bell is not worn or damaged Measure the inner diameter of the clutch bell Characteristic Clutch bell diameter standard value Ø 107 0 2 0 mm Clutch bell diameter max value allowed after use Ø 107 5 mm Eccentricity measured max 0 20 mm Removing the clutch Equip the tool with long pins screwed into position A from the outside insert the entire driven pulley in the tool and put the ce...

Page 64: ...iction material The masses must not show traces of lubricants otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1...

Page 65: ...m Remove the ball bearing retention snap ring Expel the ball bearing from the side of the clutch housing by means of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide Inspecting the driven fixed half pulley Check that there are no signs of wear on the work surface of the belt...

Page 66: ...Recommended products AGIP GREASE SM 2 Grease for the C ring of the tone wheel Soap based lithium grease containing NLGI 2 Mo lybdenum disulphide ISO L XBCHB2 DIN KF2K 20 Make sure the pins and collar are not worn reassemble 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 ...

Page 67: ... adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring Check that the contrast spring of the driven pulley does not show signs of deformation Measure the free length of the spring Characteristic Standard length 118 mm Minimum length allowed after use XXXX Refitting the clutch Preassemble the driven pulley group with spring sheath and clutch Position the spr...

Page 68: ...Nut locking clutch unit on pulley 55 60 Nm Refitting the driven pulley Refit the driven pulley assembly the clutch bell and the nut using the specific tool Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Driven pulley shaft nut 40 to 44 Nm Drive belt Make sure the driving belt is not damaged and does not have cracks in the toothed grooves Check the width of the belt Cha...

Page 69: ...ULD BREAK SUD DENLY DURING OPERATION CAUTION ON REFITTING MAKE SURE THAT DIRT DOES NOT GET INTO THE INNER BUSHING OF THE MIXER CONTROL GEAR AND THAT IT DOES NOT EXERT ANY STRESS ON THE CRANKCASE PIN N B REPLACE THE BELT EVERY 20000 KM Inspecting the rollers case 1 Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation 2 Check the roller runnin...

Page 70: ...e the movable driven half pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting N B IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE Refit the components of the assembly roller con tainer assembly with bushing limiting washer sta tionary half pulley cooling fan b...

Page 71: ... oil Remove driven pulley Remove the rear brake shoes Remove the 5 screws fixing the cover to the crankcase Remove the cover with the wheel axle and pull it out Remove the intermediate gear with the appropri ate shim washers Removing the wheel axle bearings Remove the oil seal and the seeger ring Fix the hub cover properly to avoid damaging the sealing surface with the housing Remove the wheel axl...

Page 72: ...ng the driven pulley shaft bearing Remove the seeger ring Heat the engine crankcase but do not direct the hot air towards the bearing Extract the driven pulley shaft together with the bearing with a few mallet blows Engine ENG 72 ...

Page 73: ...for wear or distortion of the toothed surfaces the bearing housings and the oil seal housings In case of anomalies replace the damaged com ponents Check capacity A of the transmission gear wear deformations etc Check the pulley shaft seating Superficial wear B may indicate irregularities in the crankcase seatings or in the pulley shaft capacities Inspecting the hub cover Check that the fitting sur...

Page 74: ...facing the bearing N B FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40 mm Adaptor Refitting the wheel axle bearing Support the hub cover on a wooden surface Heat up the hub cover using the thermal gun Preassemble the bearing on the specific punch using grease and then insert the bearing in its sea...

Page 75: ...e on the cap so that it does not interfere with the wheel axle gear when placing the transmission shaft Refitting the ub cover Apply product recommended for surfaces on the hub cap and refit cap on the crankcase Fit the 5 screws and tighten them to the specified torque N B CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVI OUS GASKETS BEFORE APPLYING A NEW ONE...

Page 76: ...ing hood Remove the four fixings shown in the figure Remove the fan cover Remove the oil piping retention band from the hood Remove the 2 screws shown in the figure Cooling fan Remove the cooling fan by acting on the three fixings indicated in the figure Engine ENG 76 ...

Page 77: ...rrying out the removal procedure in reverse tightening the retainers to the specified torque N B THE PICK UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEM BLY Locking torques N m Pick up screws 3 4 Stator screws 3 4 Flywheel and starting Removing the starter motor Remove the two clamps shown in the figure Eng...

Page 78: ...spanner 020162Y Flywheel extractor Inspecting the flywheel components Check the condition of the flywheel and any dis tortions that might cause rubbing on the stator and on the Pick Up Refitting the flywheel magneto Fit the flywheel being careful to insert the key properly Lock the flywheel nut at the prescribed torque Check the Pick Up air gap The air gap may not be modified in the fitting of the...

Page 79: ...rter on the crankcase locking the two screws to the prescribed torque N B REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD TIMING LUBRICATION FLYWHEEL AND TRANSMISSION CHAPTERS Locking torques N m Starter screws 11 13 Cylinder assy and timing system Removing the intake manifold Use an anti tampering TORX spanner to remove the two clamping screws of the intake manifold Removing the cylin...

Page 80: ...mall end Measure the internal diameter of the small end using an internal micrometer N B IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANK SHAFT CHAPTER Characteristic Rod small end standard diameter 17 0 011 0 001 Rod small end maximum allowable diameter 17 060 mm Engine ENG 8...

Page 81: ...re meter Calculate the piston pin coupling clearance Characteristic Wrist pin housing standard diameter 12 0 007 0 012 Wrist pin housing standard clearance 0 002 0 011 mm Measure the outer diameter of the piston per pendicular to the pin axis Take the measurement in the position shown in the figure To classify the cylinder piston fitting check the ap propriate table See also Cylinder piston assy E...

Page 82: ...rt the seals perpendicularly to the cylinder axis Measure the opening of the sealing rings using a thickness gauge as shown in the photograph If the values are higher than the values prescri bed in the chart substitute the rings Removing the piston Position the snap ring in detail 1 with the opening straddling the arrow printed on the tool Push detail 2 into detail 1 until the stop and extract det...

Page 83: ...es Use oil to be mixed during the fitting of the piston and the cylinder CAUTION POSITION THE ARROW PRINTED ON THE PISTON CROWN TOWARDS THE EXHAUST OPENING THE WRIST PIN SNAP RINGS MUST BE POSITIONED ON THE PISTON WITH THE SPECIFIC TOOL Recommended products AGIP CITY TEC 2T Oil Recommended oil Engine ENG 83 ...

Page 84: ... AND LAMELLA Crankcase crankshaft Splitting the crankcase halves Remove the eight crankcase union fasteners Install the special strip on the half crankcase on the flywheel side and separate the half crankcase on the flywheel side from the transmission side Specific tooling 020163Y Crankcase splitting plate Engine ENG 84 ...

Page 85: ...f crankcase or the crankshaft indifferently Using the special tool remove any bearings that have been left on the crankshaft N B The half rings must be inserted on the bearings with a few mal let blows Specific tooling 004499Y001 Bearing extractor bell 004499Y006 Bearing extractor ring 004499Y002 Bearing extractor screw 004499Y007 Half rings Using the specific tool remove any bearings left on the ...

Page 86: ...t on the dial gauge in addition check the eccentricity of diam D for which a maximum reading of 0 02 mm is permitted In the case where eccentricity is not much above prescribed levels straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp with an aluminium bushing as re quired Specific tooling 020335Y Magnetic mounting for dial gauge 020074Y Mounting base for c...

Page 87: ...e end of the stroke and loosen them again with the same angle e g 90 When the temperature has settled preload the thrust screw of the tool manually until the ball bear ing clearance is cancelled out Specific tooling 020163Y Crankcase splitting plate Refitting the crankcase halves Prepare the coupling surface with LOCTITE 510 applying a thin layer of it after degreasing the sur face using a suitabl...

Page 88: ...te in a position back from the one indicated in the figure Install the special magnetic support with dial gauge at the end of the crankshaft Check the axial clearance of the crankcase If this is not within the maximum limit allowed re peat the crankcase coupling procedure Specific tooling 020335Y Magnetic mounting for dial gauge Characteristic Axial clearance with warm crankcase 0 10 0 12 mm Axial...

Page 89: ...LE WITH THE FITTED WRENCH Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Install a new transmission side oil seal using the special tool with adapter ring The transmission side oil seal is recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Oil pump Removal Remove the 2 screws shown in the figure Engine ENG 89 ...

Page 90: ... Fuel supply Completely empty the fuel tank Remove the petrol delivery pipe and the low pressure pipe Loosen the clip and remove the cock Clean the tank and the filter of the cock with a specific solvent Refit the cock making sure that there is an O Ring Turn the cock 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 CLEANI...

Page 91: ...point of the tap Turn the engine by using the starter for five sec onds with the carburettor at minimum Take up the fuel by means of a graded burette N B THE MEASUREMENT MAY BE FALSIFIED BY THE INCOR RECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE IN THIS CASE THE TENDENCY IS TO OB TAIN A REDUCED FUEL FLOW RATE THE SUCTION OUT LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR TH...

Page 92: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 93: ... bearings on wheel hub 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 disc side insert h...

Page 94: ... with the centring ring facing to the brake disc side as shown in the photo Use an appropriate tool to insert the bearing on the side the rpm indicator detects movement Specific tooling 001467Y009 Driver for OD 42 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings 020357Y 32x35 mm Adaptor 020376Y Adaptor handle 020412Y 15 mm guide 020456Y Ø 24 mm adaptor Refitting the front wheel Follow the...

Page 95: ... THE HANDLEBAR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS Refitting Carry out the removal operations but in the reverse order observing the prescribed tightening torque Locking torques N m Handlebar fixing screw 50 55 Front fork Overhaul Seal replacement and stanchion removal Remove the wheel axle Remove the lower screw 1 Discharge the oil in the suspension Remove the stem Replace the sealing ...

Page 96: ...upper seating on the chassis LOWER AND UPPER SEATING ON THE CHASSIS Titolo Durata Valore Testo Breve 4000 car Indirizzo Immagine Lower and upper seating on the chas sis Steering bearing Steering locking ring nut Steering lock ring nut Top washer and upper bearing housing Lubricate race and balls with Z2 grease Tighten to the specified torque and then rotate the tool through 80 90 in an anticlockwi...

Page 97: ...zzo Immagine Lower and upper seating from the chassis Top washer and upper bearing housing After removing the upper seating tilt the vehicle to a side and take out the steering tube making sure mudflaps have been removed and the calliper dis connected Rear Removing the rear wheel Use a screwdriver as a lever between the drum and the cover Straighten the split pin and remove the cap Remove the whee...

Page 98: ...ng nut Then remove the shock absorber engine anchorage nut When refitting tighten the shock absorber chas sis anchoring nut and the shock absorber engine pin to the prescribed torque Locking torques N m Shock absorber engine pin torque 33 to 41 N m Shock absorber frame nut torque 20 to 25 Nm Centre stand Centre stand bolt refitting and caulking to mounting bracket Caulk the end of the pin P betwee...

Page 99: ...e to the prescribed torque Locking torques N m Stand screw torque 18 5 to 19 Nm Centre stand bolt removal from mounting bracket Remove the stand support bracket from the en gine Drill a 5 mm hole in the bracket so that the pin P can come out Suspensions SUSP 99 ...

Page 100: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 101: ...e out the plungers inject shorts blasts of compressed air through the brake fluid pipe Check that the cylinders of the internal and external body of the calliper do not show scratches or signs of erosion otherwise replace the entire calliper CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED Front brake disc Disc Inspection Remove the wheel and check for uneve...

Page 102: ...ly the tube of the special tool to the bleed screws When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system The operation is finished when just oil comes out of the bleed screws Do up the bleed screw When the operation is over tighten up the oil bleed screw to the prescribed torque N B IF AIR...

Page 103: ...WHEN CARRYING OUT THE OPERATION BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE OIL ON IT Specific tooling 020329Y Mity Vac vacuum operated pump Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Locking torques N m Oil bleed screw 8 12 Front brake pump After removing the front an...

Page 104: ...LITY SOLVENT 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 OPER ATING LIQUID Refitting Before fitting the parts must be perfectly clean and free of traces of oil diesel fuel grease etc They ...

Page 105: ...5 Sealing ring 6 Piston 7 Gasket 8 Spring Braking system BRAK SYS 105 ...

Page 106: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 107: ... of the 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 cyl...

Page 108: ...udguard Remove the side fairings Remove the 4 screws shown in the photograph Helmet bay Remove the side fairings Remove the helmet compartment by undoing the 4 screws indicated in the figure Chassis CHAS 108 ...

Page 109: ...k 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 109 ...

Page 110: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 111: ... pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam lights low beam lights tail and parking lights and their warning lights Adjusting the headlights according to the regulations currently in force Rear light parking light stop light Front and rear stop light switches Turn indicators and their warning ...

Page 112: ...IMMEDIATE MEDICAL ATTENTION IF IT ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES 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 OUT OF THE RE...

Page 113: ...COMMENDED 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 mirrors and any accessories P...

Page 114: ...INDEX OF TOPICS TIME TIME ...

Page 115: ...n is devoted to the time necessary to carry out repairs The description and code for each operation is in dicated Engine ENGINE Code Action Duration 1 001001 engine from frame removal and re fitting Time TIME 115 ...

Page 116: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Time TIME 116 ...

Page 117: ...kshaft CRANKSHAFT Code Action Duration 1 001118 Main bearings Replacement 2 001100 Clutch side oil seal Replacement 3 001099 Oil seal flywheel side Replacement 4 001117 Crankshaft Replacement Time TIME 117 ...

Page 118: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Inspection clean ing Time TIME 118 ...

Page 119: ... head assy HEAD Code Action Duration 1 001097 Cooling hood Replacement 2 001093 Spark plug Replacement 3 001126 Head Replacement 4 001013 Intake manifold Replacement 5 001178 Disc pack Replacement Time TIME 119 ...

Page 120: ...iven pulley DRIVEN PULLEY CLUTCH Code Action Duration 1 001012 Driven pulley overhaul 2 001110 Driven pulley Replacement 3 001022 Clutch Replacement 4 001155 Clutch bell housing Replacement Time TIME 120 ...

Page 121: ...Oil pump OIL PUMP Code Action Duration 1 001028 Mix movement gear socket Re placement 2 001019 Mixer belt replacement 3 001018 Mixer Replacement Time TIME 121 ...

Page 122: ...ey DRIVING PULLEY Code Action Duration 1 001066 Driving pulley Removal and refitting 2 001086 Driving half pulley replace 3 001011 Driving belt Replacement 4 001177 Variator rollers shoes Replace ment Time TIME 122 ...

Page 123: ...nsmission cover TRANSMISSION COVER Code Action Duration 1 001087 Flywheel cover Replacement 2 001135 Transmission cover bearing Re placement 3 001096 Transmission crankcase cover Re placement Time TIME 123 ...

Page 124: ...Flywheel magneto FLYWHEEL FAN Code Action Duration 1 001109 Cooling fan Replacement 2 001173 Rotor Replacement 3 001067 Stator Fitting and Refitting 4 001058 Flywheel Replacement Time TIME 124 ...

Page 125: ...burettor CARBURATOR Code Action Duration 1 001008 Carburettor Inspection 2 001063 Carburettor Replacement 3 007020 Carburettor heating tubing replace ment 4 001081 Automatic choke Replacement Time TIME 125 ...

Page 126: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001136 Exhaust emissions Adjustment Time TIME 126 ...

Page 127: ...Air cleaner AIR CLEANER Code Action Duration 1 004122 Air cleaner carburettor fitting Re placement 2 001014 Air filter Replacement cleaning 3 001015 Air filter box Replacement Time TIME 127 ...

Page 128: ...Frame STAND Code Action Duration 1 004001 Frame replace 2 004004 Stand Replacement 3 001053 Stand bolt Replacement Time TIME 128 ...

Page 129: ...R Code Action Duration 1 004159 Plates Stickers Replacement 2 004149 Shield central cover Replacement 3 004064 Front shield front part Removal and refitting 4 004015 Footrest Removal and Refitting 5 004053 Spoiler Replacement Time TIME 129 ...

Page 130: ...Rear cover REAR SHIELD Code Action Duration 1 004174 Trunk levers Replacement 2 004065 Legshield rear part Removal and refitting 3 004081 Top box lid Replacement Time TIME 130 ...

Page 131: ...de Action Duration 1 004059 Spark plug inspection flap Replace ment 2 004106 Under saddle band Replacement 3 004085 Fairing 1 Replacement 4 004105 Right side clamp Replacement 5 004131 Luggage rack support Replacement Time TIME 131 ...

Page 132: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replacement 2 004009 Rear mudguard Replacement Time TIME 132 ...

Page 133: ... Duration 1 004168 Fuel tank cap Replacement 2 005010 Tank float Replacement 3 004112 Cock carburettor hose Replace ment 4 004005 Fuel tank Replacement 5 004007 Fuel valve Replacement 6 004109 Fuel tank breather change Time TIME 133 ...

Page 134: ...ERVOIR Code Action Duration 1 005018 Oil reservoir float Replacement 2 004017 Oil reservoir Replacement 3 004095 Oil reservoir cock Replacement 4 004091 Oil reservoir hose Replacement Rear shock absorber Time TIME 134 ...

Page 135: ...03007 Rear shock absorber Removal and Refitting Steering column bearings STEERING FIFTH WHEELS Code Action Duration 1 003051 Complete fork Replacement 2 003002 Steering fifth wheels Replacement 3 003073 Steering clearance Adjustment Time TIME 135 ...

Page 136: ...004019 Handlebar rear section Replace ment 2 004018 Handlebar front section Replace ment 3 005078 Odometer glass Replacement 4 005076 Clock Cell Replacement 5 005014 Odometer Replacement 6 005038 Instrument panel warning light bulbs Replacement Time TIME 136 ...

Page 137: ...rip Replacement 4 003001 Handlebar Replacement 5 005017 Stop switch Replacement 6 002024 Front brake pump Removal and Re fitting 7 002054 Throttle or splitter transmission com plete Replacement 8 002060 Complete throttle control Replace ment 9 004162 Mirror support and or brake pump fit ting U bolt Replacement 10 002059 Right hand grip Replacement Time TIME 137 ...

Page 138: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame connection swinging arm Replacement Time TIME 138 ...

Page 139: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004068 Passenger handgrip Replacement Time TIME 139 ...

Page 140: ...2 005012 Front turn indicator Replacement 3 005067 Front turn indicator bulb Replace ment 4 005008 Headlight bulbs Replacement 5 005005 Taillight change 6 005066 Rear light bulbs Replacement 7 005022 Rear turning indicators Replace ment 8 005068 Rear turning indicator bulb Re placement Time TIME 140 ...

Page 141: ...2041 Front brake disc Replacement Grease tone wheel or drive Please take note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mistake the codes 002011 movement sen sor replacement and 005089 tone wheel replace ment in the event of noise of the indicated components The grease recommended is TUTE LA MRM 2 soap based lithium grease with Mo lybdenum disulphide In the follo...

Page 142: ...r wheel REAR WHEEL Code Action Duration 1 004126 Rear wheel tyre Replacement 2 001071 Rear wheel rim Removal and Refit ting 3 001016 Rear wheel Replacement 4 002002 Rear brake pads shoes Repl Time TIME 142 ...

Page 143: ...on 1 001020 Starter motor Replacement 2 005045 Starter motor cable harness Re placement 3 001017 Starter sprocket wheel Replace ment 4 001021 Kick starter Inspection 5 008008 Starter spring pack Replacement 6 001084 Starter lever Replacement Time TIME 143 ...

Page 144: ...Electric devices ELECTRICAL DEVICES Code Action Duration 1 005007 Battery change 2 005011 Start up contactor Replacement 3 005052 Fuse 1 Replacement 4 005054 Fuse block 1 Replacement Time TIME 144 ...

Page 145: ...S Code Action Duration 1 005001 Electrical system Replacement 2 005009 Voltage regulator Replacement 3 001094 Spark plug cap Replacement 4 001023 Control unit Replacement 5 005114 Electrical system Service Time TIME 145 ...

Page 146: ...005039 Lights switch Replacement 2 005006 Light or turning indicator switch Re placement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005016 Key switch Replacement 7 004096 Lock series Replacement Time TIME 146 ...

Page 147: ...ent 2 002012 Splitter Replacement 3 002057 Carburettor splitter transmission complete Replacement 4 002058 Mix splitter transmission complete Replacement 5 002053 Rear brake transmission complete Replacement 6 002049 Odometer cable Replacement 7 003061 Accelerator transmission adjust Time TIME 147 ...

Page 148: ...tion Duration 1 002021 Front brake hose Remov and Re fitt 2 002007 Front brake shoes pads Remov and Refitt 3 002039 Front brake calliper Removal and Refitting 4 002047 Front brake fluid and air bleed sys tem Replacement Time TIME 148 ...

Page 149: ...Steering column STEERING Code Action Duration 1 003048 Fork oil seal Replacement 2 003076 Fork sheath Replacement 3 003079 Fork stem Replacement 4 003010 Front suspension Service Time TIME 149 ...

Page 150: ...Helmet bay HELMET COMPARTMENT Code Action Duration 1 004016 Helmet compartment Removal and Refitting 2 005046 Battery cover change Time TIME 150 ...

Page 151: ...axle REAR WHEEL AXLE Code Action Duration 1 001156 Gear reduction unit cover Replace ment 2 004125 Rear wheel axle Replacement 3 001010 Geared reduction unit Service 4 003065 Gear box oil Replacement Time TIME 151 ...

Page 152: ...n 1 001164 Crankcase secondary air connection Replacement 2 001161 Secondary air filter Replacement Cleaning 3 001162 Secondary air housing Replace ment 4 001163 Muffler secondary air connection Replacement 5 001165 Secondary air reed Replacement Time TIME 152 ...

Page 153: ...8 C Carburettor 11 27 125 E Engine stop F Fuel 39 90 109 133 H Headlight 33 Horn Hub oil 29 I Identification 8 M Maintenance 7 25 S Saddle Shock absorbers 98 Spark plug 28 Stand Start up T Tank 109 133 134 Transmission 10 39 61 123 Turn indicators Tyres 10 ...

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