Gilera DNA Manual Download | Manualshive

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Personal safety

Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment

Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-

aging the environment.

Vehicle intactness

The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

The signs that you see on this page are very important. They are used to highlight those
parts of the booklet that should be read with particular care. As you can see, each sign
consists of a different graphic symbol, making it quick and easy to locate the various
topics.

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Summary of Contents for DNA

Page 1: ...ntains information tips and precautions for using your scooter It also describes features details and devices to assure you that you have made the right choice We believe that if you follow our suggestions you will soon get to know your new vehicle and it will serve you well for a long time to come This booklet forms an integral part of the scooter should the scooter be sold it must be transferred...

Page 2: ... regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre The booklet also contains instructions for simple repairs Any operations not specifically described in this manual require the use of special tools and or particular technical knowledge to carry out these operations refer to any authorised Dealer of Service Centres 2 ...

Page 3: ...ent Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee The signs that you see on this page are very important They are used to highlight those parts of the booklet that should be read with particular care As you can see each sign consists of a different graphic symbol making ...

Page 4: ...4 ...

Page 5: ...e 23 Catalytic silencer 23 Automatic transmission 24 Safe driving 25 MAINTENANCE 27 Hub oil level 28 Tyres 29 Spark plug dismantlement 30 Removing the air filter 31 Secondary air system 31 Cooling fluid level 31 Checking the brake oil level 33 Battery 34 Checking the electrolyte level 35 Long periods of inactivity 36 Fuses 37 Front light group 39 Headlight adjustment 40 Front direction indicators ...

Page 6: ...6 ...

Page 7: ...DNA Chap 01 Vehicle 7 ...

Page 8: ...ow oil warning light E Lights switch F Starter button G High beam warning light H Horn button I Turn signal switch L Ignition key switch M Digital dashboard N Lights setting switch O Low beam side lights warning light P Section reserved for electronic anti theft LED optional 8 1 Vehicle ...

Page 9: ...01_01 01_02 Instruments 01_02 A Odometer B Speedometer C Fuel gauge D Coolant temperature gauge 9 1 Vehicle ...

Page 10: ...RONGLY RECOMMEND YOU REFRAIN FROM USING THE LCD FUNC TIONS WHILE RIDING Digital lcd display The MODE button allows you to switch between the trip odometer and the clock It operates as follows if held down for less than 1 second the trip odometer is displayed when pressed again for less than 1 second the digital clock is visualised and pressing the button again for less than 1 second will bring bac...

Page 11: ...ISED NOT TO USE THE FUNCTIONS OF THE DIGITAL DISPLAY PANEL WHILE THE VEHICLE IS MOVING Setting the hour minutes function To set the clock hold down the CLOCK button for more than three seconds The numbers representing the hours will start blinking Set the hours using the SET button By pressing the CLOCK button again the numbers representing the minutes will start blinking Set the minutes using the...

Page 12: ...LOCK Ignition disabled extractable key steering lock engaged front glove box locked OFF Ignition disabled extractable key steering lock disengaged front glove box unlocked ON Starter position antitheft device disabled non extractable key glove box un locked Locking the steering wheel Turn the handlebar to the left as far as it will go turn the key to LOCK and remove the key CAUTION DO NOT TURN THE...

Page 13: ... 01_04 To set the left turn indicators flashing move lever B to the left to set the right turn indicators flashing move it to the right The lever automatically returns to the central position and the indicators remain on To turn the indicators off press the lever towards the switch 01_05 Horn button 01_05 Push the C button to sound the horn 13 1 Vehicle ...

Page 14: ...01_06 Light switch 01_06 0 Low beam and side light 1 High beam and side light 01_07 Start up button 01_07 Press the button E to start the engine after pulling one of the two brake levers 14 1 Vehicle ...

Page 15: ...p lo cated inside the helmet bay on the left hand side 01_09 Keys 01_09 The vehicle comes with one key and one copy for the ignition key switch and the seat and helmet bay locks With the keys is a plate bearing the ID number that is to be provided when requesting duplicates WARNING WE RECOMMEND KEEPING THE DUPLICATE KEY TOGETHER WITH ITS CODE IN A SAFE PLACE AND NOT ON THE VEHICLE 15 1 Vehicle ...

Page 16: ...number They should always be given when requesting spare parts We recommend that you check that the prefix and chassis number stamped on the vehicle correspond with those in the vehicle documents CAUTION BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS IMPOUNDING OF THE VEHICLE ETC 16 1 Vehicle ...

Page 17: ...DNA Chap 02 Use 17 ...

Page 18: ... tank 02_01 Refuelling 02_01 02_02 Refill the fuel tank A with unleaded petrol with 95 octane min The low fuel warning light on the dashboard signals that the fuel level has reached the reserve quantity Top up the oil tank B with the recommended oil CAUTION SHUT OFF THE ENGINE BEFORE REFUELLING WITH PETROL PETROL IS HIGHLY FLAMMABLE DO NOT LET PETROL SPILL FROM THE TANK OR WHILE REFUELLING CAUTION...

Page 19: ...D Characteristic Oil tank Plastic capacity 1 350 lt including reserve 0 400 lt Fuel tank Plastic capacity 9 lt including reserved 1 2 lt 02_03 Tyre pressure 02_03 CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD INCOR RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID ING DANGEROUS TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW 19 2 Use ...

Page 20: ...n 02_04 WARNING DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80 OF ITS MAXIMUM SPEED AVOID TWISTING THE THROTTLE GRIP FULLY OR KEEP ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD AFTER THE FIRST 1000 KM GRADUALLY INCREASE SPEED UNTIL REACHING THE MAX IMUM PERFORMANCE 20 2 Use ...

Page 21: ... ensuring the rear wheel is not touching the ground 2 Maintain the throttle twist grip in the idle position 3 Insert the key into the ignition key switch and turn it onto the ON position as the key is turned the low oil and fuel warning lights go on for a few seconds confirming the correct operation of the bulb and circuit for the low oil warning light and of the light bulb only for the low fuel w...

Page 22: ...or more than 20 seconds when attempting to start the engine 2 In the case of battery inefficiency Put the motorscooter on its stand E make sure that the rear wheel is off the ground turn the ignition key D to the ON position and use the kick starter 3 Fuel tank empty After refuelling the scooter start the engine by pressing the starter button A with the throttle at a minimum to provide maximum asp...

Page 23: ...G THE SCOOTER THAT THE EXHAUST DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS TO AVOID SERIOUS BURNS Catalytic silencer CAUTION TAMPERING WITH THE CATALYTIC MUFFLER MAY CAUSE SEVERE DAMAGE TO THE ENGINE CAUTION WHEN PARKING THE VEHICLE DUE TO THE HIGH TEMPERATURES THE CAT ALYTIC CONVERTER CAN REACH ALWAYS BE CAREFUL THAT THE MUF FLER DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS TO AVOI...

Page 24: ...and transmitted torque If you have to stop on an uphill slope traffic lights traffic jam etc only use the brake to keep the vehicle still leaving the motor running at idling speed Using the motor to keep the vehicle still can cause the clutch to overheat This problem is due to the friction of the clutch parts on the clutch bell It is therefore recommended to avoid conditions of prolonged clutch sl...

Page 25: ... the braking effect is initially lower Given these conditions it is a good idea to operate the brakes from time to time 4 Do not brake hard on a wet surface on dirt tracks or on any slippery road surface 5 If you have to brake use both brakes in order to divide the braking action between both wheels 6 Avoid starting off by mounting the scooter while it is still resting on its stand In any case the...

Page 26: ...ngerous to ride CAUTION DO NOT FORGET THAT DRIVING IN A STATE OF DRUNKENNESS OR WHEN UNDER THE EFFECT OF DRUGS OR CERTAIN MEDICINES CAN BE EXTREME LY DANGEROUS FOR ONESELF AND FOR OTHERS CAUTION ANY CHANGES TO THE VEHICLE PERFORMANCE AS WELL AS ALTERATIONS TO ORIGINAL STRUCTURAL PARTS IS STRICTLY FORBIDDEN BY LAW AND RENDERS THE VEHICLE NO LONGER CONFORMING TO THE APPROVED TYPE AND DANGEROUS FOR R...

Page 27: ...DNA Chap 03 Maintenance 27 ...

Page 28: ...l drainage tap CAUTION USING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERIOUS DAMAGE CAUTION USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT FOR OIL REPLACEMENT CONTACT AN AUTHORISED SERVICE CENTRE WHICH IS EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIEND LY AND LEGAL WAY N B THE NOTCHES ...

Page 29: ...through the tyre s tread Ensure the tyre walls are not cut and the tread is evenly worn if necessary refer to an authorised or suitably equipped workshop for the removal and refitting of the tyres CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD INCOR RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID ING DANGEROUS TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SE...

Page 30: ...ox spanner for tightening Then reattach the cap CAUTION FOLLOW THESE PROCEDURES VERY CAREFULLY TO AVOID ANY SEVERE DAMAGE THAT MAY BE CAUSED BY THE VERY POWERFUL IGNITION SYS TEM CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD USING IGNITION ELECTRONIC CENTRAL UNITS OR SPARK PLUGS OTHER THAN THE TYPES PRESCRIBED SEE TECHNICAL DATA SECTION CAN CAUSE SERIOUS DAMAGE TO THE ENGINE Chara...

Page 31: ...oling fluid level 03_06 The engine cooling system is of the liquid type with a circuit capacity of approximately 0 90 litres and the coolant constitutes of a 50 mixture of demineralised water and anti freeze glycol ethylene based solution with corrosion inhibiting agents The rec ommended coolant is pre mixed and ready for use For the engine to be running properly the coolant temperature should be ...

Page 32: ...ched when the filler cap is removed Upon refitting ensure the cover snap lips engage cor rectly against the helmet bay cover and refit the filler cap carefully so as to keep it in place If the coolant level approaches the min mark top it up with the engine cold If frequent top ups are necessary or if the expansion tank is found to be completely empty the cause of the problem is due to a fault with...

Page 33: ...tely clear the fluid level is below the min A decrease of the brake fluid level may be caused by the wear of the pads If the level is below the min mark we recommend that you contact an Authorised Piaggio Gilera Service Station to have your braking system checked If necessary top up the fluid level as follows Loosen screws B lift reservoir cover C and pour in the amount of fluid needed considering...

Page 34: ...H THE PAINTED PARTS OF THE VEHICLE THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC THAT IS IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR IF MOISTURE CONTAINED IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE THIS WILL RESULT IN INEFFICIENT BRAKING 03_09 Battery 03_09 To gain access to the battery remove the seat and hence the battery door by loos ening Phillips screw A WARNING SPENT BATTERIES ARE HARMFUL FOR TH...

Page 35: ...BATTERY ELECTROLYTE Checking the electrolyte level The electrolyte level which should be checked regularly must always be at the max imum level To reach this level use only distilled water Should it become necessary to top up the battery with water too frequently check the scooter s electrical system because the battery is being overloaded causing it to lose power quickly CAUTION ELECTROLYTE CONTA...

Page 36: ...all the engine components as well as the battery in good working order Take your vehicle to a garage as indicated in the Vehicle not used for extended periods section to have the battery removed Have the battery cleaned charged fully and stored in a dry ventilated place Recharge at least once every two months N B THE BATTERY MUST BE CHARGED WITH A CURRENT EQUAL TO 1 10 OF THE RATED CAPACITY OF THE...

Page 37: ...tomatic choke and head and taillight systems are not protected by the fuse Before replacing the fuse it is necessary to find and fix the fault Never attempt to close the circuit with any material other than the fuse CAUTION IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM NEVER DISCON NECT THE WIRING WHILE THE ENGINE IS RUNNING DO NOT TIP THE SCOOT ER TOO MUCH IN ORDER TO AVOID DANGEROUS LEAKAGE O...

Page 38: ...t tail light bulb Type All glass Power 12V 3W Quantity 2 Front turn indicator bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 LHS Rear turn indicator light bulb Type Spherical Power 12V 10W Quantity 1 RHS 1 LHS Rear sidelight and stop light bulb Type LED Quantity 8 38 3 Maintenance ...

Page 39: ...g screws located behind it Remove the headlight by loosening the 3 screws B one of which is located underneath the headlight Remove the two rubber buffers and detach the electrical connections The light bulbs are fitted onto a plastic socket and must be turned anti clockwise by about 30 degrees to be released observing the reference markings on the bulb socket Upon refitting follow the same proced...

Page 40: ...he centre of vehicle headlamp and higher than 7 10 3 Otherwise regulate the headlight by adjusting the screw A after removing the front grille N B THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS RE GARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE ve hicle IS USED Front direction indicators To replace the turn signal l...

Page 41: ...T IS SWITCHED ON THE PRESENCE OF DROPS OF WATER ON THE OTHER HAND COULD INDI CATE THAT WATER IS INFILTRATING CONTACT THE PIAGGIO AFTER SALES SERVICE NETWORK 03_16 Rear view mirrors 03_16 The mirrors must be adjusted so that the shafts are perpendicular to the vehicle s direction axis To adjust the mirror opening angle loosen the screw fitted at the end of the shaft and fasten it once the desired p...

Page 42: ...n Authorised Piaggio Service Centre to have the level of CO when idling fixed carbon monoxide emissions CAUTION WHEN ADJUSTING IDLE SPEED BE CAREFUL NOT TO TOUCH HOT PARTS OF THE ENGINE TO AVOID BURNS 03_19 Front and rear disc brake 03_19 03_20 The brake disc and pad wear is automatically compensated therefore it has no effect on the functioning of the front and rear brakes For this reason it is n...

Page 43: ... ACTIVATED THE BRAKE LEVER REPEATEDLY TO POSITION THE PADS AND RESTORE THE LEVER STROKE TO ITS CORRECT POSITION CAUTION THE BRAKING ACTION SHOULD BEGIN AFTER ABOUT 1 3 OF THE BRAKE LEVER STROKE 03_21 Puncture 03_21 The vehicle is equipped with Tubeless tyres When there is a puncture Tubeless tyres unlike tyres with inner tubes go flat very slowly This offers greater riding safety A tyre that goes ...

Page 44: ... the Battery section 5 Drain the petrol from the carburettor float chamber through the bleed cap Recommended products AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brake throttle control and mixer odometer Oil for 2 stroke engines SAE 5W 40 API SL ACEA A3 JASO MA Cleaning the vehicle Use a low pressure jet of water to soften the caked dirt and mud deposited on the painted surfaces On...

Page 45: ...D OFF AND COULD DAMAGE THE PAINTWORK NEVER USE RAGS SOAKED IN PETROL OR DIESEL OIL TO CLEAN THE PAINTED OR PLASTIC SURFACES TO PREVENT THEM LOSING THEIR SHINE AND ME CHANICAL CHARACTERISTICS WARNING WHEN WASHING THE ENGINE WITH A HIGH PRESSURE WATER JET ONLY USE FAN SPRAY JETS DO NOT PLACE THE WATER JET NOZZLE CLOSER THAN 60 CM DO NOT USE WATER AT TEMPERATURES OVER 40 C DO NOT DIRECT THE JETS DIRE...

Page 46: ...rried out by skilled personnel Check that the electrodes are properly adjusted 0 45 0 55 mm Make sure that the electrodes are clean clean them with pure petrol and a metal brush or emery cloth Check the spark plug insulating material if there are cracks replace the spark plug If the spark plug is in good condition contact an Authorised Piaggio Service Centre LACK OF COMPRESSION Spark plug loose Lo...

Page 47: ...isc Worn pads Contact an Authorised Piaggio Gilera Service Centre Air in the brake assembly Contact an Authorised Piaggio Gilera Service Centre INEFFICIENT SUSPENSION Oil leak worn limit switch bumpers worn shock absorber attachment points Contact an Authorised Service Centre IRREGULAR AUTOMATIC TRANSMISSION Deteriorated roller container or belt Contact an Authorised Service Centre 47 3 Maintenanc...

Page 48: ...INCREASED EXHAUST NOISE Deterioration of the SAS system and or of the tab Contact an Authorised Service Centre 48 3 Maintenance ...

Page 49: ...DNA Chap 04 Technical data 49 ...

Page 50: ... CHAMPION RN1C Max speed According to current legislation TECHNICAL DATA Electronic ignition A capacitor discharge microprocessor device with built in HV coil Supply With high octane 95 N O R lead free petrol mix oil via carburettor automatic mixer with variable capacity depending on the engine speed and opening of throttle valve petrol pump Intake By means of a compression valve on the casing 50 ...

Page 51: ...ank In plastic of capacity 1 3 lt including reserve 0 500 lt Fuel tank Plastic capacity 9 lt including reserved 1 2 lt Rear hub oil 85 cc Wheel rim Front 3 00 x 15 light alloy Rear 3 50 x 14 light alloy Front tyre 120 70 15 Rear tyre 140 70 14 Chassis Double steel diagonal beam Front brake disc brake with hand activated hydraulic control lever on the extreme right of the handlebars Rear brake Ø 17...

Page 52: ... Chassis to engine support with swinging arm Exhaust silencer Expanding absorption type with double catalytic converter Saddle height 810 mm Wheel base 1350 mm Maximum length 1970 mm Maximum width 780 mm Dry weight 99 kg Maximum load Driver only 52 4 Technical data ...

Page 53: ...04_01 53 4 Technical data ...

Page 54: ...Kit equipment Wrenches box spanner 16 mm 13mm flat wrench twin screwdriver The tools are located under the seat in an appropriate container 54 4 Technical data ...

Page 55: ...DNA Chap 05 Spare parts and accessories 55 ...

Page 56: ... PARTS CAUSES YOUR WARRANTY RIGHTS TO EXPIRE WARNING PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES THAT ARE RECOG NISED AND GUARANTEED FOR USE IT IS THEREFORE ESSENTIAL IN ORDER TO CHOOSE AND MOUNT THE ACCESSORIES CORRECTLY TO CONTACT AN AUTHORISED DEALER OR SERVICE CENTRE THE USE OF NON ORIGINAL ACCESSORIES MAY AFFECT THE STABILITY AND OPERATION OF YOUR VE HICLE AND REDUCE SAFETY LEVELS WITH POTENT...

Page 57: ...DNA Chap 06 Programmed maintenance 57 ...

Page 58: ...waiting until the next scheduled service to solve it All scheduled maintenance services must be carried out at the specified intervals even if the stated mileage has not yet been reached Punctual scooter servicing is essential to ensure your warranty remains valid For any further information concern ing Warranty procedures and Scheduled Maintenance please refer to the Warranty Booklet EVERY 2 YEAR...

Page 59: ...KM 35000 KM AND 55000 KM Hub oil level check Spark plug electrode gap replacement Air filter clean Oil mixer throttle linkage adjustment Coolant level check Brake control levers greasing Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test 59 6 Programmed maintenance ...

Page 60: ...Driving belt checking Coolant level check Steering adjustment 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 CO regulation in the Adjusting the engine idle section...

Page 61: ...check Brake control levers greasing Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check SAS box sponge cleaning Vehicle and brake test road test See the regulations of the Secondary air system section AT 20000 KMS AND 40000 KMS Hub oil change Spark plug electrode gap replacement 61 6 Programmed maintenance ...

Page 62: ...ternal cleaning check Odometer gear greasing Steering adjustment 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 CO regulation in the Adjusting the engine idle sect...

Page 63: ...ment Coolant level check Odometer gear greasing Steering adjustment Brake control levers greasing Brake pads check condition and wear Flexible brake tubes replacement Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check SAS box sponge cleaning 63 6 Programmed maintenance ...

Page 64: ...r filter clean Idling speed adjustment Oil mixer throttle linkage adjustment Driving belt replacement Variable speed rollers replacement Mixer belt replacement Coolant level check Radiator external cleaning check Odometer gear greasing Steering adjustment Brake control levers greasing Brake pads check condition and wear Flexible brake tubes replacement Brake fluid level check 64 6 Programmed maint...

Page 65: ... AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brake throttle control and mixer odometer Oil for 2 stroke engines SAE 5W 40 API SL ACEA A3 JASO MA AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AGIP CITY TEC 2T Mixer oil synth...

Page 66: ...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 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 66 6 Programmed mainten...

Page 67: ...brake 42 Display 10 F Fuses 37 H Headlight 40 Horn 13 Hub oil 28 I Identification 16 K Key switch 12 Keys 15 L Light switch 14 M Maintenance 27 57 58 Mirrors 41 S Scheduled maintenance 58 Spark plug 30 Start up 14 T Technical Data 49 Transmission 24 Tyre pressure 19 Tyres 29 67 ...

Page 68: ...ts parts or accessories which it considers necessary to improve the product or which are required for manufacturing or con struction reasons Not all versions models shown in this publication are available in all countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproduction of this publ...

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