Derbi GP1 50 cc Workshop Manual Download Page 37

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3. LOWER COWLING COVER

• Extract the 2 securing screws (Philips 6x16 with was-
her)

Time taken:

17 Minutes

N.B.

TO CONTINUE WITH THE HELMET HOLDER WE NEED
TO CONTINUE DISMANTLING THE FRONT PART, SIN-
CE THE PETROL TANK FRONT BREATHER PIPE PASSES
THROUGH THE HELMET HOLDER.

4. WATER-OIL TANK COVER

• Extract the 2 top screws (Philips 5x12).

Time taken:

19 Minutes

5. SIDE COVERS

• Pull them gently backwards.

Time taken:

20 Minutes

Summary of Contents for GP1 50 cc

Page 1: ...GP1 50 cc WORKSHOP MANUAL...

Page 2: ...rand s dealers and sub dealers Due to its constant commitment to improving its products DERBI NACIONAL MOTOR S A Sociedad Unipersonal reserves the right to introduce any modifications it deems fit wit...

Page 3: ......

Page 4: ...ANTLING THE ENGINE TRANSMISSION COVER DISMANTLING DRIVEN PULLEY SHAFT SUPPORT BEARINGS FITTING DRIVEN PULLEY SHAFT SUPPORT BEARINGS DISMANTLING DRIVEN PULLEY CHECKING CLUTCH BELL HOUSING DISMANTLING C...

Page 5: ...TLING THE ENGINE FITTING THE STATOR FITTING THE MAGNETO COVER MAGNETO AND STARTING DISMANTLING THE STARTER MOTOR DISMANTLING THE MAGNETO CHECKING THE MAGNETO COMPONENTS FITTING THE MAGNETO FITTING THE...

Page 6: ...SEBAC FORKS MARZOCCHI FORKS DISMANTLING THE FRONT SUSPENSION INSPECTING THE FRONT FORKS SHOCK ABSORBER AND SWINGING ARM SHOCK ABSORBER AND SWINGING ARM DISMANTLING INSPECTION FRONT WHEEL AND BRAKES F...

Page 7: ...G ELECTRICAL SYSTEM GP1 50C C WIRING DIAGRAM GP1 50C C WIRING DIAGRAM SWITZERLAND CHECKING CONNECTORS STEPS FOR THE INSPECTION DIGITAL INSTRUMENTS UNIT IGNITION AUTOMATIC CHOKE AND LIGHTS BATTERY RECH...

Page 8: ...STOP WHEN TICKING OVER HIGH FUEL CONSUMPTION EXCESSIVELY NOISY EXHAUST ENGINE OVERHEATING FAULTS TRANSMISSION AND BRAKES PULLING OR ABNORMAL CLUTCH OPERATION POOR BRAKING POWER BRAKES OVERHEATING ELE...

Page 9: ...t are non inflammable or with a high flammability point Lubricate all working surfaces before assembling excluding tapered joints After assembly check that all components have been correctly fitted an...

Page 10: ...ON VALUE Engine type Diameter per stroke Cubic capacity Compression ratio Carburettor CO regulation Tick over Air filter Ignition system Lubrication ENGINE Single cylinder 2 stroke 40 x 39 3 mm 49 40...

Page 11: ...ifugal Z 19 Z 45 Depression fuel pump supplying lead free petrol via the carburettor CHARACTERISTIC DIMENSION VALUE Transmission TRANSMISSION Automatic speed variator with expandable pulleys tra pezoi...

Page 12: ...perated disk 245 mm Hydraulically operated disk 180 mm DOT 4 CHARACTERISTIC DIMENSION VALUE BRAKING SYSTEM Front wheel type Front tyre inflated pressure Rear wheel type Rear tyre inflated pressure 120...

Page 13: ...ir jet Secondary minimum air orifice Minimum mixture screw initial opening Choke jet Choke air jet Choke needle travel Fuel entry orifice 209HA 32 Libre 2 5 mm 1 1 2 50 1 5 mm 11 mm 1 0 mm CHARACTERIS...

Page 14: ...lock securing device M8x125 Brake disk front wheel securing device M6x100 Brake disk calliper forks securing device M10x1 5 Rear wheel securing device M14x200 Drag plate wheel securing device M6x100...

Page 15: ...ark plug Oil sump drain plug Rear hub cover bolts DESCRIPTION TORQUES N M TORQUES M KG 40 44 55 60 40 44 12 13 40 44 3 4 12 13 22 24 4 5 10 11 12 13 25 30 3 5 12 13 4 4 4 5 5 6 4 4 4 1 2 1 3 4 4 4 0 3...

Page 16: ...40 211 4 211 40 218 40 218 40 225 40 397 40 404 40 404 40 411 40 411 40 418 40 418 40 425 PISTON 39 943 39 95 39 95 39 957 39 957 39 964 39 964 39 971 40 143 40 15 40 15 40 157 40 157 40 164 40 164 4...

Page 17: ...lay E 0 25 0 50 Play F 2 20 0 75 Play E 0 25 0 50 Play F 2 20 0 75 Play E 0 25 0 50 Play F 2 20 0 75 Play E 0 25 0 50 Play F 2 20 0 75 Play F 2 20 0 75 SLOT PACKING SYSTEM Fit the cylinder without pos...

Page 18: ...17 SISTEMA DE MONTAJE DE ESPESORES Packing Packing Spacing NAME THICKNESS 0 4 0 6 0 8 MEASURE A 2 80 3 04 3 04 3 24 3 24 3 48...

Page 19: ...paired parts together This includes gears cylinders pistons and other parts submitted to natural wear in pairs Paired parts must always be reassembled or replaced together 4 While dismantling the moto...

Page 20: ...grease to the retaining ring edges TAB SPACER WASHERS AND SPLIT PINS 1 After removing them replace all tab spacer washers 1 and split pins Bend the tabs to fit the flat surfaces of the bolt or nut onc...

Page 21: ...to the force to be applied to it See the figure on the side 4 Axle SPECIAL TOOLS 1 The following special tools are needed for assembly and for complete and exact adjustments Only use the proper specia...

Page 22: ...E IMAGE DESCRIPTION Air heater Flywheel extractor Crankc splitting plate Half pulleys fixing sheath Starter sprocket retainer Bearing fitting stand Impeller retaining spanner 020151Y 020162Y 020163Y 0...

Page 23: ...ger Magnetic stand and comparator REFERENCIA IMAGEN DESCRIPCI N 020168Y 020169Y 020170Y 020325Y 020331Y 020332Y 020334Y 020335Y Oil seal fitting drift on half crankcase Water pump drive shaft spanner...

Page 24: ...Change output pinion tool REFERENCIA IMAGEN DESCRIPCI N 020350Y 020656Y 020340Y 020080Y 020168Y 020341Y 020342Y 00G05300131 Electric system diagnostic device Compass flywheel stop spanner Crankcase ha...

Page 25: ...ure and wear Check for possible fluid leaks petrol oil coolant brake fluid Check for possible cracks in the fuel pipes Check that all the control elements are operating correctly Check that the brakes...

Page 26: ...eck Vehicle and brake test Road test ACTION AT 1000 KM OR 4 MONTHS Hub oil level Check Spark plug Electrode gap Change Air filter Cleaning Oli mixter Throttle linkage Adjust Cooling fluid level Check...

Page 27: ...vel Check Transmissions Lubricate Nuts bolts and fasteners Check Suspensions Check Headlight Adjust Tires inflation and wear Check Vehicle and brake test Road test Hub oil level Check Spark plug spark...

Page 28: ...levers Grease Brake pads Check condition wear Brake fluid level Check Transmisions Lubricate Nuts bolts and fasteners Check Suspensions Check Electrical system and battery Check Headlight Adjust Tires...

Page 29: ...nge Fuel oil mixter belt Change Cooling fluid level Check Radiator External cleaning check Speedometer cable Grease Steering Adjust Brake levers Grease Brake pads Check condition wear Braking circuit...

Page 30: ...s replace the spark plug with one of the recommended type Engage the thread with the correct inclination and the screw the spark plug by hand as far as it will go then tighten it using the box spanner...

Page 31: ...e the dipstick and check the oil mark reaches just below the second notch from the bottom 4 Screw the dipstick back in with the correct torque Oil synthetic multidegree SAE 75W 85 API GL4 Replacement...

Page 32: ...oil mixture Let the filtering element drain and then squeeze it with your hands without crushing it Let it dry and refit it Mineral oil with special additives to increase its adhesiveness ISO VG 150...

Page 33: ...ing plate which must be aligned to that shown on the mixer body as indicated in the figure While performing this operation the engine must be fed with a 2 oil fuel mixture at least 0 5 litres if the t...

Page 34: ...E SKIN THE EYES AND CLOTHING IN CASE OF CONTACT RINSE GENE ROUSLY WITH WATER CAUTION THE BRAKE FLUID IS HIGHLY CORROSIVE TAKE CARE NOT TO SPILL IT ON THE PAINTWORK CAUTION THE BRAKE FLUID IS HYGROSCOP...

Page 35: ...al line which separates the lit area from the dark region is no more than 9 10 and not less than 7 10 of the height of the headlight measured from the ground 3 If this is not the case adjust the headl...

Page 36: ...n M3 from under the cowling Time taken 15 Minutes Extract the 8 top screws Philips 3 6x14 self tappers with washer and the 2 side screws Philips 6x16 with washer Pull the cowling backwards slightly to...

Page 37: ...B TO CONTINUE WITH THE HELMET HOLDER WE NEED TO CONTINUE DISMANTLING THE FRONT PART SIN CE THE PETROL TANK FRONT BREATHER PIPE PASSES THROUGH THE HELMET HOLDER 4 WATER OIL TANK COVER Extract the 2 top...

Page 38: ...aken 23 Minutes 7 PETROL TANK COVER Extract the bottom covers left and right by remo ving the 6 screws Philips 5x16 with washer and the two air inputs 3 screws 1 Philips 3x10 self tapper 1 Philips 3 6...

Page 39: ...rt as in the image Time taken 35 Minutes ATTENTI N TO PREVENT THE SHIELD FROM DROPPING THE USE OF A UNEX CLAMP OR SIMILAR IS RECOMMENDED 8 HELMET CARRIER Remove the battery and cables Extract the 6 se...

Page 40: ...joining the two fairings Time taken 53 Minutes 10 SIDE COVERS Remove the 2 securing screws 1 Philips 6x16 with l washer and 1 Philips 3 6x10 self tapper and the turn indicator wire Time taken 60 Minut...

Page 41: ...ct the 4 front ALLEN 5 screws Extract 6 screw top rear with back nut 3 DISCONNECT THE SECONDARY AIR PIPE 4 EXTRACT CARBURETTOR AIR INLET PIPE Cut the pipe flange accessing as in the image N B TO FIT I...

Page 42: ...m the supporting tab and pull out the filter starting at the rear 6 EXTRACT CARBURETTOR Loosen the clamp using a ratchet type tool Disconnect the choke cable petrol pipe and air inlet pipe from the ca...

Page 43: ...42 Extract the carburettor to gain access to all its parts N B FIT IN REVERSE ORDER TAKING SPECIAL CARE WITH THE WIRING PETROL OIL WATER...

Page 44: ...t the H T cable from the spark plug 8 Remove the spring from the left hand front part of the Silent bloc 9 Remove the Allen bolt from the right hand front part of the Silent bloc 10 Remove the two bol...

Page 45: ...NG THE DRIVEN PULLEY SHAFT BEARING Slightly heat the crankcase on the inside to avoid damaging the painted surface Remove the bearing using the driven pulley shaft or a pin of the same diameter N B IF...

Page 46: ...t usurata or damaged To measure the inner diameter of the bell clutch Characteristic Clutch bell diameter standard value 0107 0 2 0 mm Clutch bell diameter max value allowed after use 0 107 5 mm Found...

Page 47: ...masses must exhibit no traces of lubricants in that case check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CEN TRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN...

Page 48: ...roller bearing Remove the roller bearing from the side of the clutch using the specific device N B ADEQUATELY SUPPORT THE HALF PULLEY TO PREVENT THE DRIVE BELT SLIDING SURFACE FROM BEING DISTORTED Spe...

Page 49: ...the mobile half pulley Assemble the half pulley on the bushing Recommended products Molybdenum disulphide grease and lithium soap Make sure the pins and collar are not worn reassemble the pins and co...

Page 50: ...r 020362Y 12 mm guide 020171Y Roller bearing drift INSPECTING THE CLUTCH SPRING Make sure that the driven pulley contrast spring is not de formed Minimum length allowed after use Characteristic Standa...

Page 51: ...g clutch assembly on pulley 55 60 Nm REFITTING THE DRIVEN PULLEY Fit the driven pulley assembly the clutch bell housing and the nut using the specific tool Specific tooling 020565Y Compass flywheel st...

Page 52: ...ION DO NOT TWIST OR BEND THE BELT WHEN REFITTING IT CAUTION BEFORE REFITTING THE BELT CAREFULLY LUBRICATE THE PIN AND THE MIXER DRIVE GEAR BUSHING WITH OIL MA KING SURE THIS IS FREE FROM ANY LOAD N B...

Page 53: ...teristic Maximum allowable diameter 20 12 mm Standard diameter 20 021 mm REFITTING THE DRIVING PULLEY Manually move the mobile driven pulley by pulling it towards the clutch unit and insert the belt k...

Page 54: ...spanner Locking torques N m Tightening torque plus angle 18 20 90 N m DISMANTLING ENGINE PINION Loosen Change output engine pinion bush M16x125 Specific tool 00G05300131 Tightening torques N m Change...

Page 55: ...e gear compartment Specific tooling 020363Y 20mm guide 020376Y Handle for punches 020358y 37x40 adaptor REMOVING THE DRIVEN PULLEY SHAFT BEARING Remove the seeger ring from inside the cover Remove the...

Page 56: ...that the mating surface is not dented or distorted If any anomalies are found replace the hub cover INSPECTING THE HUB COVER Make sure the coupling surface is not dented or deformed If faults are dis...

Page 57: ...020358y 37 x40 adaptor REFITTING THE WHEEL AXLE BEARING Heat the crankcase on the clutch side with the thermal gun After lubricating the bearing outer plate fit the bearing using the specially design...

Page 58: ...ening torque 11 13 N m FLYWHEEL COVER REMOVING THE STATOR Remove the stator 3 implantations indicated in photo Remove the pick up 2 implantations indicates in photo Remove the stator complete with wir...

Page 59: ...on in inserting the strap in the groove Tighten the 8 fixing screws FLYWHEEL AND STARTING REMOVING THE STARTER MOTOR Remove the fixings shown in the picture REMOVING THE FLYWHEEL MAGNETO Lock the flyw...

Page 60: ...WHEEL MAGNETO Fit the flywheel taking care to properly insert the key Tighten the flywheel locknut with the prescribed torque Check that the pick up air gap is 0 5 0 6 mm No adjust ment of the air gap...

Page 61: ...AINING PARTS AS DESCRIBED IN THE CHAP TERS CYLINDER CYLINDER HEAD VALVE GEAR LUBRICA TION FLYWHEEL AND TRANSMISSION Locking torques N m Starter motor screws 11 13 CYLINDER ASSY AND TIMING SYSTEM REMOV...

Page 62: ...ETER EXCEEDS THE MAXIMUM ALLO WABLE VALUE OR IF IT SHOWS SIGNS OF WEAR OR OVER HEATING PROCEED TO REPLACE THE CRANKSHAFT AS DES CRIBED IN THE CHAPTER CRANKCASE AND CRANKSHAFT Characteristic Standard d...

Page 63: ...figure To classify the cylinder piston mating check the appropria te table See also Cylinder piston assy INSPECTING THE CYLINDER Check the cylinder does not show signs of seizures If it does proceed...

Page 64: ...2 Insert part 3 inside part 1 position the assembly in the pis ton ring housing and push part 3 home N B REFIT THE REMAINING COMPONENTS FOLLOWING THE OPERATIONS FOR THEIR REMOVAL IN THE REVERSE ORDER...

Page 65: ...lenia Hi Scooter 2 Tech Oil Recommended oil INSPECTING THE TIMING SYSTEM COMPONENTS CAUTION CHECK THE LEAK TIGHTNESS OF THE REED VALVE ASSY NO LIGHT BE VISIBLE BETWEEN VALVE AND HOUSING INSPECTING THE...

Page 66: ...rankcase using four M6 screws of adequate length Remove the crankshaft from the transmission side half crankcase Specific tooling 020163y Crankcase splitting plate REMOVING THE CRANKSHAFT BEARINGS The...

Page 67: ...ny bearing which remained on the crankcase Specific tooling 001467Y007 Bell for bearings external 0 54 mm 001467Y006 20 mm pliers REFITTING THE CRANKSHAFT BEARINGS Heat the bearings in oil at approx 1...

Page 68: ...re not too far off the prescribed values straighten the crankshaft by acting with a wedge in between the coun terweights or by using vice with aluminium mouth guards according to your needs Specific t...

Page 69: ...case splitting plate REFITTING THE CRANKCASE HALVES Prepare the mating plane by applying a thin layer of LOCTI TE 510 after cleaning the surface with and adequate solvent e g acetylene trichloride Hea...

Page 70: ...d and comparator Characteristic Axial play with warm crankcase 0 10 0 12 mm Axial play with cold crankcase 0 06 0 08 mm Limit value with cold crankcase 0 02 0 03 mm LUBRICATION CRANKSHAFT OIL SEALS Re...

Page 71: ...40Y Punch for fitting oil guard magneto and trans mission OIL PUMP REMOVAL Remove the two screws shown in the figure Remove the fairlead from the crankcase as indicated in the figure REFITTING For the...

Page 72: ...following mass flow measurement may be carried out 1 Start the engine warm it up to the standard operating temperature and shut it down 2 Detach the fuel inlet tube on the carburettor and insert it i...

Page 73: ...hexagonal bolt 8M125x35 ZnB Allen bolt Arm securing bolt washer Fork arm plug Fork pipe plug ring Fork spring Hydraulic piston spring Hydraulic piston ring Fork arm retainer washer Fork arm pipe Hydra...

Page 74: ...Fork arm securing ring Fork arm guide bush Arm guide bush washer Fork arm retainer Oil seal ring Fork arm dust guard Fork arm assembly 8M125x30 Allen bolt Arm securing bolt washer Fork plug ring Fork...

Page 75: ...RING COLUMN THEREBY PREVENTING THEM FROM BEING SCRATCHED Extract the top closing bolt Remove the top bolt ATENCI N THE BOTTOM BAR OF THE FORKS WILL COME FREE HOLD IT TO PREVENT IT FROM FALLING Have re...

Page 76: ...t the spring and the preload spacer Extract the oil seal dust guard together with its security circlip Firmly separate the bar from the fork stem Extract the elements Dust guard 1 Oil seal 2 Washer 3...

Page 77: ...With the aid of some X shaped chocks and a comparison meter fitted on a fixed support determine the degree of non alignment of the bar Service limit 0 4 mm Check the length of the suspension spring as...

Page 78: ...m 1 5 1 9 m kg 1 Refit all the components Readjust forks to the chassis Refit the front fairing Connect the headlight cables the turn indicators and the dashboard NOTA TIGHTEN ALL BOLTS TO THEIR NOMI...

Page 79: ...Hexagonal nut Shock absorber assembly 10M150x60 ZnB Allen bolt D10D125 ZnB Washer 10M150 ZnB Hexagonal nut 10M150x60 ZnB Allen bolt Shock absorber bottom separator bush Swinging arm outer stop bush S...

Page 80: ...ber 4 Extract Swinging arm shaft nut Wheel axle nut Washers swinging arm Shafts Swnging arm INSPECCI N 1 Inspect Swinging arm play Play Tighten the joint shaft nut or replace the bushes Swinging arm v...

Page 81: ...protector Wheel separator bush C ALL 10M 150x60 D912 8ZnB bolt DIN 125 A ST front wheel axle D15 DIN 125 A ST flat washer D 934 wheel axle head nut D 245 front brake disk FR 6x20 Zn B10 9 disk securi...

Page 82: ...t left side 3 Raise Front wheel Put a suitable support under the engine 4 Extract Front wheel axle Front brake disk assembly Dustguard spacer Front wheel INSPECTING THE FRONT WHEEL 1 Inspect Front whe...

Page 83: ...eplace Distortion limits for the front wheel Radial a 0 5 mm Lateral b 0 8 mm 5 Check Front wheel bearings Bearings allow play in the wheel hub or the wheel does not turn freely Replace Retaining ring...

Page 84: ...e brake pipe and the calliper Tighten to nominal torque Tighten the brake banjo bolt Check brake fluid level Bleed the brake system pipe consult Bleeding the brake system pipe in this chapter Check th...

Page 85: ...ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER IS OPERATING FULLY THIS IS ACHIEVED BY PUMPING THE LEVER UNTIL THE PADS ARE AGAINST THE DISK IF NOT THE BRAKES WILL NOT WORK THE FIRST TIME THE LEV...

Page 86: ...e condition of the braking force to see if any resis tance is noted or any loss of fluid Checking the brake lever master cylinder visual check Extract the master cylinder consult Extracting the front...

Page 87: ...wheel Unscrew the mounting bolts and extract the disk Fitting the brake disk Fit the brake disk onto the front wheel so that side 2 faces outwards Apply a temporary blocking device to the threads of...

Page 88: ...the result that almost all the movements of the brake lever are transmitted directly to the calliper for braking Air however compresses easily When air enters the brake system pipes the movement of th...

Page 89: ...PTIES COMPLETELY OF BRAKE FLUID AT ANY TIME THE DURING BLEEDING PROCEDURE PERFORM THE BLEEDING PROCE DURE ALL OVER AGAIN FROM THE BEGINNING SINCE AIR WILL HAVE ENTERED THE PIPE TAP THE BRAKE PIPE LIGH...

Page 90: ...PARTS TO DETERIORATE IF OIL IS SPILT ON ANY PART IT WILL BE DIFFICULT TO CLEAN COMPLETELY AND MAY DETERIORATE THE RUB BER USED IN THE DISK BRAKE 7 ON HANDLING THE DISK BRAKE LININGS OR THE DISK TAKE C...

Page 91: ...t Front wheel 3 Tighten Front wheel axle Axle nut front wheel ATTENTION BEFORE TIGHTENING THE WHEEL AXLE PUSH THE FRONT FORKS DOWN SEVERAL TIMES HOLDING THE HANDLE BARS TO CHECK THEIR OPERATION Axle n...

Page 92: ...GP1 secondary chain Secondary chain coupling Bearing Bearing separator Connector Washer Wheel tensioner Wheel tensioner cap 6M100x60 chain tensioner bolt Aut 6M100 DIN 985 8 ZnB nut Plate side bush G...

Page 93: ...L PUSH THE WHEEL FORWARDS TO REMOVE THE DRIVE CHAIN THEN EXTRACT THE WHEEL BACKWARDS TO AVOID THE BRAKE CALLIPER DISMANTLING THE REAR DISK CALLIPER Loosen the bolt at the bottom end of the flexible br...

Page 94: ...r corresponding to the front brakes Check the condition of the braking force to see if any resis tance is noted or any loss of fluid WARNING DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER...

Page 95: ...Extracting the rear main cylinder Remove the cover protecting the main cylinder The bol ts securing the cover also support the cylinder Extract the bolt and remove the flexible hose from the brake cyl...

Page 96: ...ylinder change the seals Checking the rear calliper main cylinder Check that the anti dust boots are not damaged If they are change them Check that the piston return is not damaged If it is renew it C...

Page 97: ...mm Bleeding the brake system pipe The brake fluid has a very low compression coefficient with the result that almost all the movements of the brake lever are transmitted directly to the calliper for b...

Page 98: ...the purge valve quickly while keeping the brake on Release the brake NOTA CHECK THE FLUID LEVEL FREQUENTLY DURING THE BLEEDIING OPERATION AND REPLENISH THE RESERVOIR WITH BRAKE FLUID WHEN NECESSARY IF...

Page 99: ...NING BRAKE PARTS DO NOT USE ANY OTHER TYPE OF LIQUID FOR CLEANING THESE PARTS PETROL ENGINE OIL OR ANY OTHER PETROLEUM DISTI LLATE WILL CAUSE RUBBER PARTS TO DETERIORATE IF OIL IS SPILT ON ANY PART IT...

Page 100: ...pressed with a finger there should be a play of 12 18mm If adjustment is nee ded proceed as follows loosen the wheel nut and adjust the tensor by turning thern dockwise giving the same number of turn...

Page 101: ...D FIRMLY AND THERE IS NO RISK OF IT FALLING 2 Extract Pinion See the DISMANTLING THE ENGINE section in CHAP TER 5 3 Extract Rear wheel See the WHEEL AND REAR BRAKE section 4 Extract Coupling circlip 1...

Page 102: ...r Replace the whole chain 3 Clean Drive chain Place the chain in a container with petrol and brush it to re move as much of the dirt as possible Then remove the chain from the petrol dry and lubricate...

Page 103: ...sion chain Check the drive chain tension When pressed with a finger there should be a play of 12 18mm If adjustment is nee ded proceed as follows loosen the wheel nut and adjust the tensor by turning...

Page 104: ...tank filler cap Warm the engine up to its operational tempe rature so to eliminate any air bubble within the main circuit Shut the engine off let it cool down and hence check the coolant level in the...

Page 105: ...haft turning the spanner clockwise left handed thread As the thread is fully disengaged extract the shaft with the aid of pliers Specific tooling 020169Y Water pump drive shaft spanner Using the speci...

Page 106: ...nkcase Insert the shaft with bearings in its housing by pushing and turning it at the same turn anticlockwise for tightening Turn it rapidly until the thread reaches the end Should this operation prov...

Page 107: ...ining the system Remove the cylinder head Remove the two fixing screws and hence the thermostat CHECK 1 Visually ensure the thermostat is not damaged 2 Fill a metallic container with approx 1 litre of...

Page 108: ...pecific tooling 020331 Y Digital multimeter 020151Y Air heater Characteristic Thermostat check Opening start temperature 60 2 C REFITTING Refit the thermostat onto the head following the removal opera...

Page 109: ...ch Right hand front turn indic 12v 10W amber bulb Left hand front turn indic 12v 10W amber bulb Right hand rear turn indic 12v 10W amber bulb Left hand rear turn indic 12v 10W amber bulb Side Brake li...

Page 110: ...ndic 12v 10W amber bulb Left hand rear turn indicator 12v 10W amber bulb Right hand rear turn indicator 12v 10W amber bulb Left hand rear turn indicator 12v 10W amber bulb Side Brake light assembly 12...

Page 111: ...comes loose bend the pin 1 and refit the terminal in the connector 6 Connect Connector N B THE TWO PARTS OF THE CONNECTOR MAKE A SOUND WHEN THEY FIT TOGETHER 7 Check the circuit with a Multimeter N B...

Page 112: ...ERAL TIMES ADJUST THE METER SELECTOR TO THE X1 POSITION ADJUST THE GAUGE TO ZERO INSPECTION STEPS NUMBER CONNECTION POLARITY 1 2 3 4 5 6 7 8 9 10 11 12 DIGITAL INSTRUMENTS UNIT DESCRIPTION Battery Con...

Page 113: ...112 4 1 6 5 2 3 IGNITION 7 Electronic central unit Magneto Pick Up Ignition key switch Spark plug Control circuit Digital instruments unit...

Page 114: ...113 4 1 6 5 2 3 AUTOMATIC CHOKE AND LIGHTS 7 8 Magneto Voltage regulator Automatic choke Rear light Digital instruments unit Front sidelight bulbs Dipped headlight bulbs Main beam headlight bulbs...

Page 115: ...4 1 6 5 2 3 BATTERY RECHARGE AND STARTING 7 8 9 10 Magneto Voltage regulator 7 5 amp fuse 12v 6AH battery Starter relay Starter motor Rear light with LED Ignition key switch Starter button Stop butto...

Page 116: ...13 14 Voltage regulator Ignition key switch 7 5 amp fuse 12v 6AH battery Starter button Starter relay Starter motor Stop buttons Fuel level sensor Coolant temperature sensor Mixer oil level sensor Pho...

Page 117: ...1 6 5 2 3 TURN INDICATORS AND HORN 7 8 9 10 Voltage regulator Ignition key switch 7 5 amp fuse 12v 6AH battery Horn button Horn Turn indicator bulbs Turn indicator switch Digital instruments unit Diod...

Page 118: ...carry out measurements on the recharge coil on the pick up see table and continuity measurements using the special tes ter If faults are identified through the above inspections proceed by replacing...

Page 119: ...HE VALUES ARE STATED FOR AMBIENT TEMPERATURE CHECKING THE STATOR AT OPERATING TEMPERATURE WILL BRING THE VALUES ABOVE THE STATED ONES Electric characteristic Stator brown ground 170 pick Up Stator bla...

Page 120: ...no anomalies are identified replace the regulator c If the replacement of the regulator does not solve the fault check the electric connections Specific tooling 020331Y Digital multimeter Characterist...

Page 121: ...N B BEFORE CARRYING OUT INSPECTIONS ON THE REGULA TOR AND ITS ELECTRICAL SYSTEMS IT IS ALWAYS ADVI SABLE TO CHECK FOR CONTINUITY BETWEEN THE BLACK CABLE AND GROUND N B TO MAINTAIN THE BATTERY BETWEEN...

Page 122: ...y by the battery If the lights do not go on check the switch and its cable if these are not damaged or faulty replace the regu lator as definitely faulty Specific tooling 020331Y Digital multimeter FA...

Page 123: ...GHER AMPERAGE Characteristic Fuse DISMANTLING THE BATTERY WARNING ENSURE THAT YOU DISCONNECT THE CABLE FROM THE NEGATIVE TERMINAL FIRST FILLING WITH ELECTROLYTE WARNING DO NOT REMOVE THE ALUMINIUM SEA...

Page 124: ...FROM THE BATTERY WARNING REFILL THE BATTERY WITH ELECTROLYTE UNTIL THE CON TAINER HAS COMPLETELY EMPTIED Make sure all the electrolyte has emptied out Tap the bottom lightly as indicated above if any...

Page 125: ...CHARGED ACORDING TO THE METHOD SPECIFIED ABO VE TAKE CARE HOWEVER SINCE THE BATTERY S PER FORMANCE MAY BE NOTABLY REDUCED IF CHARGED IN CONDITIONS OTHER THAN THE ABOVE NEVER REMOVE THE CLOSING STRIP...

Page 126: ...N IS SERIOUS GET MEDICAL ATTENTION INTERCHANGEABILITY A BATTERY THAT DOES NOT REQUIRE MAINTENANCE CAN ONLY GIVE ITS BEST PERFORMANCE IN COMBINATION WITH THE ELECTRICAL SYSTEM OF THE CORRECT MACHI NE T...

Page 127: ...e ins pecting the charging conditions Remove the battery A Carry out the recharging by following the method and ac cording to the voltage at the battery terminals WARNING THIS BATTERY IS THE HERMETIC...

Page 128: ...127...

Page 129: ...r colgged or dirty Choke failure it remains inserted Clutchs slippage Defective sliding of movable pulleys Worn driving belt Rollers worn presence of oil dirt Replaced pump or tubing Remove wash in so...

Page 130: ...ions circuit continuity me chanical sliding and power supply Check the battery charge condition If the battery shows signs of sulfation replace it Before installing the new battery charge it for eight...

Page 131: ...d needle valve operation ENGINE TENDS TO CUT OFF AT FULL THROTTLE Float valve defective Check float and needle sliding Fuel vent pipe colgged Resorte the proper tank aeration CAUSES POSSIBLE WORK Idle...

Page 132: ...ents if damaged EXCESSIVE EXHAUST NOISE NOISE INCREASE CAUSES POSSIBLE WORK No coolant within the cooling circuit Air bleed badly performed Top up the level and ensure there are no leaks within the ci...

Page 133: ...let the carbon deposits fall inside the silencer CAUSES POSSIBLE WORK Clutch slippage or irregular operation Ensure shoes open and close freely Check no grease is present on the shoes Check the shoes...

Page 134: ...r scored replace the affected parts as necessary INSUFFICIENT BRAKING BRAKING SYSTEM FAILURE Air bubbles in the braking hydraulic system Carefully bleed the hydraulic system spring action of the brake...

Page 135: ...the positive terminal marked To charge the battery follow the instructions described in Chapter ELECTRICAL EQUIPMENT ELECTRICAL SYSTEM BATTERY CAUSES POSSIBLE WORK Suspensions faulty Check integrity a...

Page 136: ...bearing races and re place if they show signs of uneven wear NOISY SUSPENSION CAUSES POSSIBLE WORK Front suspension components damaged Check for the absence of noise coming from the fork during compr...

Page 137: ...136 SUSPENSION OIL LEAKAGE CAUSES POSSIBLE WORK Rear shock absorber faulty Replace the shock absorber assembly Inner fork hydraulic damper damaged Replace the hydraulic damper...

Page 138: ...created by w w w ciandisseny com...

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