Gilera Runner Purejet 2007 Workshop Manual Download Page 191

Page: 191 / 257

Water pump - overhaul

- Remove the rpm sensor /coolant delivery hose

clamp

- Remove the transmission cover

- Remove the mixer

- Position the tool as shown in the picture

N.B.

WHEN SECURING THE TOOL, PAY ATTENTION NOT TO
OVERLOAD THE PLASTIC IMPELLER.

Specific tooling

020620Y

Water pump impeller stop

- Remove the mixer/water pump drive-belt with the

two crown wheels

- Remove the snap ring of the pump bearing stay

- Remove the steel washer

- Using the air heater, warm up the crankcase in

the area around the water pump bearings as

shown in the picture.

Runner Purejet

Cooling system

COOL SYS - 191

Summary of Contents for Runner Purejet 2007

Page 1: ...WORKSHOP MANUAL 633499 Runner Purejet ...

Page 2: ...nges to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction 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 Reproducti...

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

Page 4: ...G TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP PURE JET INJECTION INJ PJ BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 6: ...by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and split pins upon refitting After remov...

Page 7: ...through pump with flow rate varying according to the engine speed and throttle opening Fuel supply Air assisted direct fuel injection into the combustion chamber The electric pump is controlled by the injection ECU Inlet By means of a compression valve on the casing Max power to the wheel Max torque to the wheel Cooling system Through circulation of cooling liquid Transmission TRANSMISSION Specifi...

Page 8: ...AKES Specification Desc Quantity Front brake Ø 220 mm disc brake with hydraulic linkage r h brake lever Rear brake Ø 175 mm disc hydraulically controlled via lever on left hand side of handlebar Wheels and tyres WHEELS AND TIRES Specification Desc Quantity Front tire dimension 120 70 12 Rear tire dimension 130 70 12 Pressione pneumatici Ruota anteriore 1 6 bar Ruota posteriore 1 8 bar Circles 3 50...

Page 9: ... Frame swing arm bolt 33 41 Shock absorber frame nut 20 25 Shock absorber engine bolt 33 41 Wheel axle pin 100 125 Stand pin 18 5 19 Stand screws 18 5 19 Bloccaggi di sicurezza SOSPENSIONE ANTERIORE Name Torque in Nm Dado forcella 20 25 Fork screw 20 25 Front wheel axle 45 50 Bloccaggi di sicurezza FRENO ANTERIORE Name Torque in Nm Brake fluid pump hose fitting 13 to 18 Nm Brake fluid pipe callipe...

Page 10: ...the head studs 3 4 Crankcase compressor studs 3 4 Impiegare dadi nuovi Overhaul data Assembly clearances Cylinder piston assy THE DIAMETER OF THE CYLINDER MUST BE MEASURED 15MM FROM THE HEAD RESTING LEVEL ACCOPPIAMENTO TRA PISTONE E CILINDRO Name Initials Cylinder Piston Play on fitting Cilindro M 39 997 40 004 39 943 39 95 0 047 0 061 Cilindro N 40 004 40 011 39 95 39 957 0 047 0 061 Pistone O 40...

Page 11: ...ANELLI DI TENUTA Name Description Dimensions Initials Quantity Anello di tenuta 40 A 0 10 0 25 Anello di tenuta 1 Magg 40 2 A 0 10 0 25 Anello di tenuta 2 Magg 40 4 A 0 10 0 25 Crankcase crankshaft connecting rod PISTON TEST PROBE Name Descripti on Dimensio ns Initials Quantity Piston Ø 12 0 007 0 012 P 0 002 0 011 Test probe Ø 12 0 005 0 001 Q 0 002 0 011 Runner Purejet Characteristics CHAR 11 ...

Page 12: ...BE Name Descripti on Dimensio ns Initials Quantity Connect ing rod Ø 17 0 011 0 001 G 0 002 0 012 Roller cas ing Ø 2 5 0 0 007 F 0 002 0 012 Test probe Ø 12 0 005 0 001 H 0 002 0 012 FITTING CATEGORY ROD SMALL END ROLLER CASING TEST PROBE Name Descripti on Dimensio ns Initials Quantity Rod small end Cat 3 Ø 17 0 011 0 007 Rod small end Cat 2 Ø 17 0 007 0 003 Rod small end Cat 1 Ø 17 0 003 0 001 Ro...

Page 13: ...specifications AGIP CITY HI TEC 4T Oil for flexible transmission lubrication acceleration control mixer and odome ter Synthetic oil that passes SAE 5W 40 API SL ACEA A3 JASO MA specifications AGIP CITY HI TEC 4T Oil for air filter sponge Synthetic oil that passes SAE 5W 40 API SL ACEA A3 JASO MA specifications AGIP GP 330 Grease for brake control levers throttle stand White calcium complex soap ba...

Page 14: ...NENT PLUS Coolant Monoethylene glycol antifreeze fluid CU NA NC 956 16 AGIP GREASE SM 2 Greasing the driven pulley bushing Soap based lithium grease with NLGI 2 Molybdenum Disulphide ISO L XBCHB2 DIN KF2K 20 Characteristics Runner Purejet CHAR 14 ...

Page 15: ...INDEX OF TOPICS TOOLING TOOL ...

Page 16: ...6 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm ø bearings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bearings 001467Y014 Pliers to extract ø 15 mm bearings Tooling Runner Purejet TOOL 16 ...

Page 17: ...01467Y021 Extraction pliers for ø 11 mm bearings 001467Y029 Bell for bearings O D 38 mm 002465Y Pliers for circlips 004499Y Camshaft bearing extractor 004499Y007 Half rings 006029Y Punch for fitting fifth wheel seat on steer ing tube Runner Purejet Tooling TOOL 17 ...

Page 18: ...els from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020080Y Punch for removing 12 mm bearings 020150Y Air heater support 020151Y Air heater 020162Y Flywheel extractor Tooling Runner Purejet TOOL 18 ...

Page 19: ...e 020164Y Driven pulley assembly sheath 020166Y Pin lock fitting tool 020168Y Water seal punch mount on half crank case 020169Y Water pump crankshaft fitting and remov al spanner 020170Y Water pump mixer command gear ex tractor Runner Purejet Tooling TOOL 19 ...

Page 20: ...71Y Punch for driven pulley roller bearing 020209Y Spring hook 020265Y Bearing fitting base 020272Y Piston position check tool 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump Tooling Runner Purejet TOOL 20 ...

Page 21: ...Stores code Description 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020334Y Multiple battery charger Runner Purejet Tooling TOOL 21 ...

Page 22: ...gnetic support for dial gauge 020340Y Flywheel and transmission oil seals fitting punch 020357Y 32 x 35 mm adaptor 020358Y 37x40 mm adaptor 020359Y 42x47 mm adaptor 020362Y 12 mm guide 020363Y 20 mm guide Tooling Runner Purejet TOOL 22 ...

Page 23: ...cription 020409Y Multimeter adaptor Peak voltage detec tion 020376Y Adaptor handle 020412Y 15 mm guide 020439Y 17 mm guide 020444Y Test probe removal fitting tool 020456Y Ø 24 mm adaptor Runner Purejet Tooling TOOL 23 ...

Page 24: ...452Y Tube for removing and refitting the driven pulley shaft 020460Y Scooter diagnosis and tester 020481Y Control unit interface wiring 020565Y Flywheel lock calliper spanner 020469Y Reprogramming kit for scooter diagnosis tester Tooling Runner Purejet TOOL 24 ...

Page 25: ...gnostic tester programming software 020615Y Carbon dam ring fitting kit 020616Y Fuel pressure control kit 020617Y Air pressure check kit 020620Y Water pump impeller stop 020621Y HV cable extraction adaptor Runner Purejet Tooling TOOL 25 ...

Page 26: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 27: ... chart EVERY 2 YEARS Action Brake fluid change Coolant change AT 1 000 KM Action Hub oil level Check Replace Oil mixer throttle linkage adjustment Steering adjustment Brake control levers greasing Brake fluid level check Safety locks check Electrics Check Tyre pressure and wear check Vehicle and brake test road test AT 5 000 KM 25 000 KM 35 000 KM 55 000 KM Action Hub oil level Check Replace Spark...

Page 28: ...cement Fuel filter replacement Air filter cleaning Oil mixer throttle linkage adjustment Variator rollers Check wear Mixer belt replacement Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Coolant level check Transmission elements lubrication Safety locks check Suspensions check Electrics Check Headlight adjustment check Tyre pressure an...

Page 29: ...rake pads check condition and wear Brake fluid hoses replacement Brake fluid level check Coolant level check Transmission elements lubrication Safety locks check Suspensions check Electrics Check Headlight adjustment check Tyre pressure and wear check Vehicle and brake test road test Spark plug We inform you that in order to avoid water infiltra tions through the spark plug cap the following modif...

Page 30: ...G 6 YCA Locking torques N m Spark plug 11 14 Nm Hub oil Replacement Remove the oil charging cap Unscrew the oil drain plug B and allow the oil to flow out completely Rescrew the drain plug B and refill the engine with oil until it touches the full hole apporx 75cc The level must correspond to the second notch starting from the bottom as shown in the picture WARNING DO NOT REMOVE THE OIL PLUG STRAI...

Page 31: ...mixture of 50 fuel and oil CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER Recommended products AGIP CITY HI TEC 4T Oil for air filter sponge Synthetic oil that passes SAE 5W 40 API SL ACEA A3 JASO MA specifications Runner Purejet Maintenance MAIN 31 ...

Page 32: ...ng the transmissions check that they move perfectly within the sheath Lubricate the cable with the recommended prod uct applying a plastic bag as shown in the picture If the cable does not move perfectly due to pos sible fraying replace both the cable and the sheath Recommended products AGIP CITY HI TEC 4T Oil for flexible transmis sion lubrication acceleration control mixer and odometer Synthetic...

Page 33: ...ER CAUTION WHEN REMOVING OR WHERE THERE IS NO MORE OIL IN THE TANK PROCEED WITH THE BLEEDING ACTIVITIES OF THE MIXER AS FOLLOWS WITH THE MIXER MOUNTED ON THE VEHICLE AND WITH THE ENGINE OFF DISCONNECT THE MIXER TUBE FROM THE CARBU RETTOR AND LOOSEN THE BLEED VALVES SEE ARROW IN PICTURE UNTIL OIL STARTS TO FLOW TIGHTEN THE SCREW START THE ENGINE AND WAIT FOR OIL TO COME OUT FROM THE DELIVERY TUBE T...

Page 34: ...nd ensure the vehicle axle is perpendic ular to the screen Trace a horizontal line on the screen with a ground height of 65 67 cm start the engine and block the gas knob so the vehicle stays still switch on the headlight engage the lower beam and direct it so the horizontal demarkation line between the area in shadow and lit up area does not go above the horizontal line traced on the screen To acc...

Page 35: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 36: ...peration Tear or irregular functioning Ensure the masses move at the touch of a finger and return as normal Ensure there is no grease on the masses Ensure the seals work correctly area of work at the centre Ensure the clutch bell is not scored Check Rpm at start of drag 4 000 revs per min Rpm on full throttle with rear wheel braked 3 6 max 7000 7500 revs per min WARNING NEVER ALLOW THE ENGINE TO R...

Page 37: ...uent inspections and thorough maintenance Fre quently check that the fluid level fully covers the plates other wise restore the level adding distilled water never use natural water even if it is drinking water and check fluid density at the same time If the vehicle is not used for some time 1 month or more the battery needs to be recharged periodically The bat tery tends to discharge completely wi...

Page 38: ...ng the steering even after making the above adjust ments check the seats in which the ball bearings rotate re place if they are recessed Noisy suspension NOISY SUSPENSION Possible Cause Operation Noisy suspension If the front suspension is noisy check the efficiency of the front suspension the condition of the ball bearings and relevant lock nuts the limit switch rubber stoppers and the movement s...

Page 39: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 40: ... 5 Starter button 6 Right front turn indicator 7 Key switch 8 Fuel level sender 9 Voltage regulator 10 Coil 11 Spark plug 12 Fuel injector 13 Air injector 14 Water temperature sensor 15 Throttle body pos 16 Flywheel magneto 17 Starter motor 18 15A fuse 19 Diagnostics outlet 20 Battery Electrical system Runner Purejet ELE SYS 40 ...

Page 41: ...rn 30 7 5A fuse 31 Turn indicator switch 32 Left front turn indicator 33 Horn button 34 Commutatore lampeggiatori 35 Light switch 36 Rear stop light switch Conceptual diagrams Ignition IGNITION SECTION Specification Desc Quantity 1 Battery 12V 9Ah 2 Fuse 15A 3 Key switch contacts 4 Voltage regulator 5 15A fuse 6 HV coil 7 Ignition spark plug 8 Flywheel magneto 9 Pick up Runner Purejet Electrical s...

Page 42: ...or lamps 12V 10w 6 Turn indicator switch 7 Plug with contacts 8 Parking light bulb 12V 5W 9 Rear positioning bulbs 12V 5W 10 Service light warning light 12V 12W 11 3 bulbs for lighting instrument 12V 1 2W 12 Light switch 13 Low beam bulb 12V 35W 14 High beam bulb 12V 55W 15 High beam warning light 12V 1 2W 16 Fuse 7 5A 17 7 5A 18 Key switch contacts 19 Fuse 15A 20 Battery 21 Fuse 15A Electrical sy...

Page 43: ...lywheel magneto 3 CPU 4 7 5A fuse 5 15A fuse 6 Starter remote control 7 Starter motor 8 Starter button 9 Brake light filament 12V 21W 10 Front brake stop button 11 Rear stop light switch 12 Battery 12V 9Ah 13 Fuse 15A 14 Key switch contacts 15 Mixer oil warning light control Runner Purejet Electrical system ELE SYS 43 ...

Page 44: ...stance 27Ω 0 5W 4 Water temperature gauge 5 7 5A fuse 6 Key switch contacts 7 Fuse 15A 8 Battery 12V 9Ah 9 Horn button 10 Claxon in c c 11 Fuel resreve light 12 Fuel indicator 13 Fuel level sending unit 14 Turn indicator device com 15 Oil warning light 16 Oil mix warning light com 17 Diagnostic light Electrical system Runner Purejet ELE SYS 44 ...

Page 45: ...13 Water thermometer 14 Fuel gauge 15 Low oil warning light 16 High beam warning light 17 Rhs turn signal warning light 18 Lhs turn signal warning light 19 Headlamp warning light 20 Instrument lighting Checks and inspections Battery recharge circuit The recharge circuit has a three phase generator with permanent magneto The generator is directly connected to the voltage regulator The voltage regul...

Page 46: ... Ohm Also check that each yellow wire is isolated from the ground If non conforming values are found repeat the checks on the stator if incorrect values continue to occur replace the stator or repair the wiring Voltage regulator check With the battery fully charged measure the volt age in the battery poles with engine at high speed The voltage must not exceed 15 2 volt If higher voltage is found r...

Page 47: ...ted voltage 12V Rated power 0 25 kW Left rotation viewed from pinion side Connection to engine with pinion and crown wheel on transmission side crankshaft Control with button Tests to perform to check the electrical starter Static test Remove the left side panel Check the resistance of the induced brush unit Reference value or equal to 1 Ohm Use a lift to adequately support the vehicle Remove the ...

Page 48: ...of the starter Disconnect the fuel injection connector Turn to ON Select the PARAMETERS function Start the engine making sure the vehicle cannot move long enough to measure the rpm and starter absorption Absorption at drag rpm from 15 to 25A Drag rpm from 500 to 550 rpm N B THE VALUE OF DECLARED RPM IS THAT INDICATED BY THE DIAGNOSTIC TESTER Specific tooling 020460Y Scooter diagnosis and tester Ca...

Page 49: ...or circuit is managed by an inter mittent device If there are any problems with this circuit check The 7 5A fuse indicated in the photograph after removing the front cowling Using a multimeter that the BLACK BLUE cable to the turn indicator connector has a voltage of 12V To check the efficiency of the bulbs apply a ten sion of 12V to the WHITE BLUE cable of the Runner Purejet Electrical system ELE...

Page 50: ... Ω See also Legshield The oil mix warning light performs a timed check of 3 every time the key is turned to ON The check is managed by the turn indicator device which ap plies a voltage of 12 v to the oil warning light bulb If on turning the key to ON the control is not carried out check Bulb efficiency The 7 5A fuse shown in the photograph after re moving the front casing Using a multimeter and t...

Page 51: ...D SEEK IMMEDIATE MEDICAL ATTENTION IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK MAGNESIUM MILK BATTERED EGG OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION THE BATTERIES PRODUCE EXPLOSIVE GAS KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY ...

Page 52: ...ce that requires the most careful monitoring and diligent maintenance The maintenance rules are 1 Check the level of the electrolyte Check regularly that the electrolyte level is at up per level Use only distilled water to top up the level If the battery needs topping up very frequently check the vehicle electrics the battery is probably working in overload conditions which will lead to rapid dete...

Page 53: ...ry charger selector on the type of battery to recharge at a current of 0 9A for around 6 8 hours The connections with the power supply source must be made by connecting the corresponding poles with and with The battery caps must be removed during charging Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger 4 Cleaning the battery The battery should always be kept clean ...

Page 54: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 55: ...brake line clamps on the trans mission cover as shown in the figure Loosen the 5 rear wheel clamping screws to re move the brake calliper Remove the brake calliper using the 2 screws shown in the figure Remove the gas control cable from the throttle body Runner Purejet Engine from vehicle ENG VE 55 ...

Page 56: ...ss the union pipe downwards Hold the pipe downwards and pull the safety ring upwards Extract the connector from the fuel injector If the connector is difficult to extract do not force it too much and combine the rotation movement with pushing pulling stresses Engine from vehicle Runner Purejet ENG VE 56 ...

Page 57: ... side Remove the electric connectors from the fuel and air injector Remove the electric connector from the throttle body Remove the plastic clamp connecting the electric cable of the throttle body to the air pipe shown in the figure Runner Purejet Engine from vehicle ENG VE 57 ...

Page 58: ...le as shown Remove the starter wiring from the relay and from the grounding wire Remove the plastic clamp connecting the starter wiring to the swinging arm Remove the screw fixing the fuel piping clamp to the engine on the transmission side Engine from vehicle Runner Purejet ENG VE 58 ...

Page 59: ...piping from the en gine and discharge the fluid Remove the air filter sucking sleeve Remove the lower suspension fixing Use two 17 mm Allen wrenches to remove the engine swinging arm fixing pin Remove the oil mixer pipe from the tank Runner Purejet Engine from vehicle ENG VE 59 ...

Page 60: ... to the engine Make sure that the fuel line connectors are per fectly inserted in the injector Check that the rubber buffers installed on the fuel lines are properly placed to prevent damage to the lines caused by rubbing CAUTION THE FUEL PRESSURE IN THE SUPPLY SYSTEM IS AP PROX 4 BAR REPLACE THE FUEL LINES IF DAMAGED Locking torques N m Swinging arm engine 33 41 Nm Rear brake cal liper 20 25 Nm R...

Page 61: ...INDEX OF TOPICS ENGINE ENG ...

Page 62: ...maging 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 inside N B WHEN RE...

Page 63: ... 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 central scr...

Page 64: ...aterial The masses must not show traces of lubricants otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EX HIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE AN OTHER 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 mm Pi...

Page 65: ... 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 If ther...

Page 66: ...ed products AGIP GREASE SM 2 Grease for the tone wheel revolving ring 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 gr of grease This operation must be done through one of the holes inside the bus...

Page 67: ...the new oil seals and the O rings on the mobile half pulley Fit the half pulley on the bushing CAUTION WHILE FITTING THE MOBILE DRIVEN HALF PULLEY TAKE CARE NOT TO DAMAGE THE OIL SEALS Check that pins and collar are not worn refit pins and collar Use a bent tip oiler to lubricate the pulley unit with approx 6 gr grease This operation must be per formed through one of the holes into the bushing unt...

Page 68: ... the driven pulley group with spring sheath and clutch Position the spring with the sheath Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar Reassemble the nut securing the clutch and tight en to the prescribed torque CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK ET WRENCH WITH SMALL CHAMFER CAUTION POSIT...

Page 69: ...ck the width of the belt Characteristic Transmission belt Minimum width 17 5 mm Removing the driving pulley Lock the driving pulley using the appropriate tool Remove the central nut with the related washer then remove the drive and the plastic fan Remove the stationary half pulley Remove the belt washer and remove the mobile half pulley with its bushing being careful that the rollers and contrast ...

Page 70: ...urface and that the metallic insert does not come out of the plastic shell borders 4 Check the integrity of the sliding blocks of the contact plate Check that the internal bushing shown in the fig ure is not abnormally worn and measure inside diameter A Measure outside diameter B of the pulley slid ing bushing shown in the figure CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING Characteristic Driving...

Page 71: ...ghten the lock nut to 20 Nm and then perform a final 90 locking in order to prevent the rotation of the driving pulley N B REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSE QUENTLY DAMAGING THE CRANKSHAFT KNURLING Specific tooling 020451Y Starting ring gear...

Page 72: ...e of the gear compartment using the appropriate punch Specific tooling 020363Y 20 mm guide 020376Y Adaptor handle 020358Y 37x40 mm adaptor Removing the driven pulley shaft bearing Remove the seeger ring inside the cover Remove the oil seal from the outside Remove the centring dowels and position the cover on a plane Position the special tool on the internal track of the bearing and remove said bea...

Page 73: ...hat the fitting surface is not dented or dis torted If faults are found replace the hub cover Refitting the driven pulley shaft bearing Support the inner track of the bearing from the outside of the hub cover with the specific tool posi tioned under the press and insert the driven pulley axle Refit the oil seal flush with the cover Specific tooling 020452Y Tube for removing and refitting the drive...

Page 74: ... 020151Y Air heater 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42x47 mm adaptor Refitting the ub cover Refit the complete wheel axis Refit the intermediate gear being careful of the two shim adjustments Apply LOCTITE 510 for surfaces on the hub cov er and refit it with the complete pulley shaft Insert the 5 screws and tighten them to the pre scribed torque N B CLEAN THE CONTACT SURFACES OF...

Page 75: ...5 mm Allen wrench to remove the flywheel lock nut Specific tooling 020565Y Flywheel lock calliper spanner Use a specific extractor to remove the flywheel Specific tooling 020162Y Flywheel extractor Remove the two studs of the revolutions sensor to the coolant inlet pipe Runner Purejet Engine ENG 75 ...

Page 76: ...ng and revolution sensor Locking torques N m Flywheel nut 40 to 44 N m Refitting the stator To refit perform the removal procedures in the reverse direction Refitting the flywheel cover Fit the rubber seal on the flywheel con nector and around the inlet coolant hose Engine Runner Purejet ENG 76 ...

Page 77: ...hat the two longer golden screws are inserted in the 2 top holes and are also responsi ble for restraining the secondary air box Cylinder assy and timing system Remove the flywheel cover using the 4 screws shown in the figure Removing the cylinder head Use a TORX 20 wrench to remove the air feeding line from the injection head as shown in the figure Runner Purejet Engine ENG 77 ...

Page 78: ...ews shown in the figure Remove the spark plug Remove the temperature sensor shown in the figure To remove the air injector extract the dust cover and use a screwdriver to remove the injector as shown in the figure N B BE CAREFUL NOT TO DAMAGE THE INJECTOR PLASTIC SUPPORT Engine Runner Purejet ENG 78 ...

Page 79: ...wo screws as shown in the figure Remove the head inside recirculation duct as shown in the figure Remove the head using the 4 screws as shown in the figure Removing the cylinder piston assy Remove the cylinder holding the piston in order to prevent damage Runner Purejet Engine ENG 79 ...

Page 80: ... THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSITION IN CASE OF REUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small 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 DESCRIBE...

Page 81: ...r 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 Runner P...

Page 82: ... or deformed To classify the fitting refer to the tables See also Cylinder piston assy Inspecting the piston rings Alternatively insert the 2 sealing rings into the cylinder Insert the rings in an orthogonal position relative to the cylinder axis using the piston Measure the sealing ring opening by a feeler gauge as shown in the figure If the values are higher than those prescribed on the chart re...

Page 83: ...cific tool with the aperture in the position shown on the tool as in the figure Place the wrist pin stop ring into position using a punch Specific tooling 020166Y Pin lock fitting tool Fit the wrist pin stop using the plug as shown in the figure Specific tooling 020166Y Pin lock fitting tool Runner Purejet Engine ENG 83 ...

Page 84: ... gauge position Lock the tool by the nuts used to secure the head Turn the engine shaft to the dead centre position dial gauge rotation inversion point Measure the difference with the reset value Refer to the table to identify the thickness of the cylinder base gasket to use for refitting The correct identification of the thickness of the cylinder base gasket allows maintaining the correct compres...

Page 85: ... them in crossed sequence to the prescribed torque Locking torques N m Head fixing nuts 10 11 Nm Refit the head inside recirculation duct as shown in the figure Check that the O Ring is in good working condi tion Fit the coolant outlet union on the head with rel evant O ring by tightening 2 screws to the prescri bed torque Locking torques N m Coolant outlet union fixing screws 3 4 Nm Introduce the...

Page 86: ...Refit the temperature sensor shown in the figure and tighten to the prescribed torque Locking torques N m Temperature sensor 18 22 Nm Spark plug 11 14 Nm Refit the injection head including the fuel injector and pressure regulator and tighten to the prescri bed torque Locking torques N m Injection head fixing screw 3 4 Nm Use a TORX 20 wrench to refit the air feeding pipe from the injection head Se...

Page 87: ...he photo Specific tooling 020615Y Carbon dam ring fitting kit Position the specific tool with the rung facing the injector as shown in the figure Use the specific tool to tighten the carbon dam ring seat as shown in the figure Take several steps to ensure a correct insertion into the seat Refit the air injector in its seat on the head quickly to prevent the carbon dam ring from expanding again Spe...

Page 88: ...kcase half clamping screws shown in the figure Insert the guard on the crankshaft as shown in the figure Use the specific tool to remove the crankcase half on the flywheel side Place the tool being careful to correctly centre it Use a 17 mm Allen wrench to remove the crank case half on the flywheel side N B IF SEPARATION REQUIRES FORCING USE A THERMAL GUN TO HEAT THE CRANKCASE IN THE BENCH BEAR IN...

Page 89: ... side using four M6 screws of an adequate length Remove the crankshaft from the transmission side half crankcase Specific tooling 020163Y Crankcase splitting plate Removing the crankshaft bearings Bearings may be left on the crankcase halves or on the crankshaft Use the specific tool to remove any bearings left on the crankshaft N B HALF RINGS MUST BE INSERTED ON THE BEARINGS BY STRIKING THEM WITH...

Page 90: ...lly heat the container with a thermal gun until the oil temperature reaches approx 150 Check the temperature using a multimeter provi ded with thermal probe N B IF THE BEARINGS WERE IMMERSED INTO HOT OIL THEY WOULD BE IMMEDIATELY DAMAGED Place the crankshaft on the special support Alternately introduce the 2 bearings to insert them home If required use a specific pipe to ensure their in sertion N ...

Page 91: ...ge 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 support for dial gauge 020074Y Support base for checking crankshaft ...

Page 92: ...tion of the reference dowels Refitting the crankshaft Place the transmission side crankcase half on two wooden supports Refit the water pump rotor note that the thread ing is anticlockwise Use the thermal gun to heat the bearing seat to approx 120 N B MAKE SURE THAT THERE IS THE NECESSARY SPACE IN THE LOWER SIDE TO INSERT THE CRANKSHAFT Insert the crankshaft using a firm movement until the bearing...

Page 93: ... the fitting surface using the recommen ded product applying a thin layer after degreasing the surface with a suitable solvent e g trichloro ethylene Recommended products Loctite 510 Liquid sealant Gasket Assemble the equipment need to close the crank case half screws wrench Heat the crankcase half on the flywheel side us ing the thermal gun with the same procedure on the transmission side crankca...

Page 94: ...clean precise movement Insert at least three clamping screws and tighten up rapidly Insert the other 5 screws and tighten them to the specified torque Locking torques N m crankcase coupling screws 11 13 Move the crankcase separation plate 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 clearan...

Page 95: ... body manifold Remove the air piping union from the injection head using a Torx 25mm wrench Remove the air piping support bracket fixing screw from the transmission covers Remove the 4 screws fixing the air compressor to the crankcase as shown in the figure Remove the air compressor Runner Purejet Engine ENG 95 ...

Page 96: ...ec centric as shown in the figure Use a feeler gauge to measure the axial play of the control roller by placing the blade between roller and one of the two shim adjustments Characteristic Standard axial play XXX Allowable limit after use XXX Check that the O ring exhibits no breakage or squashing Engine Runner Purejet ENG 96 ...

Page 97: ...c at its lower dead point Insert the compressor into the crankcase cor rectly placing the reference dowels Refit the sealing ring Refit the 4 fixing screws tightening to the prescri bed torque Locking torques N m Air compressor fixing screws 3 4 Nm Refit the air pipe support bracket fixing screw on the transmission cover Refit the air piping union on the injection head Runner Purejet Engine ENG 97...

Page 98: ...e smaller diameter N B USE OF THE TOOL IS NOT COMPATIBLE WITH THE MOUNTED KEY Specific tooling 020340Y Flywheel and transmission oil seals fitting punch Install a new oil seal on the transmission side us ing the specific tool provided with adapter ring The transmission side oil seal can be recognised by the larger diameter Specific tooling 020340Y Flywheel and transmission oil seals fitting punch ...

Page 99: ...t the throttle body Refit the flywheel stator Refit the mixer Refit the driven pulley Refit the driving pulley Oil pump Removal Remove the transmission cover Remove driving pulley Remove the 2 screws shown in the figure Remove the pipe gasket from the case as shown in the figure Runner Purejet Engine ENG 99 ...

Page 100: ...e pump case See also Removing the driving pulley Removing the driving pulley Refitting To refit perform the removal procedures in the reverse direction Perform purging after refitting using the screw shown in the figure Engine Runner Purejet ENG 100 ...

Page 101: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 102: ...de the rpm indicator detects movement as shown in the photograph Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y009 Driver for OD 42 mm bearings 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 disk side insert han dle on the side the rpm indicator detects move ment as shown i...

Page 103: ...0412Y 15 mm guide With a hot air gun heat the seat of the bearing on the side the rpm indicator detects movement Insert the internal spacer with the centring ring facing to the brake disk side as shown in the photo Use an appropriate tool to insert the bearing on the rpm indicator movement detector side Specific tooling 020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide See also...

Page 104: ...AR FORWARD TO AVOIDING DAMAGING THE TRANSMISSIONS See also Front handlebar cover Rear handlebar cover Refitting When refitting tighten to the prescribed torque and apply the recommended grease to the threaded cone Recommended products AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C NLGI...

Page 105: ...emoval Front mudguard Front handlebar cover Rear handlebar cover Overhaul Replacing o ring Remove the wheel axle Remove the screw 4 Remove the stanchion 3 Remove the dust guard 1 Insert the new sealing ring after lubricating the inside parts of the ring and paying attention not to damage it Insert the stanchion appIying the recommended product to the clean surface Lock the screw 4 Recommended prod...

Page 106: ...remove sealing ring 2 and seeger 3 Using nut 4 remove the spring stem and bushing The damper is an integral part of the stem and cannot therefore be overhauled so if you need to work on the damper loss of fork oil carry out the operations mentioned above and replace the shock absorber stem unit When refitting tighten to the prescribed torque and apply the recommended grease to the threadlock nut S...

Page 107: ...NLGI 2 ISO L XBCIB2 Locking torques N m Locking torque 50 to 60 Nm Steering column Removal Removing upper and lower frame area Only remove the seats if it is strictly necessary Using the special tool remove the upper fifth wheel seat by putting the special tool into the lower part of the headstock as indicated in the figure By inserting the punch into the top of the tube remove the lower fifth whe...

Page 108: ...roperly Using the special tool remove the fifth wheel seat on the steering tube as shown in the photograph by applying small mallet blows Specific tooling 020004Y Punch for removing fifth wheels from headstock Always use a new fifth wheel seat on refitting Using the special tool refit the fifth wheel seat with the aid of a few mallet blows and bring it as far as the stop shown in the photo Specifi...

Page 109: ...055Y Wrench for steering tube ring nut See also Front handlebar cover Rear handlebar cover Refitting Steering wheel ring nut refitting After locking the first ring nut in place lock the second ring nut using a specific tool Specific tooling 020055Y Wrench for steering tube ring nut Locking torques N m Locking torque 30 to 40 Nm Rear Runner Purejet Suspensions SUSP 109 ...

Page 110: ...scribed torque in a cross over pattern Locking torques N m Rear wheel 20 25 Nm Shock absorbers Removal To replace the shock absorber you just need to remove the battery access flap to get and remove the shock absorber frame anchorage nut Then remove the shock absorber engine anchorage nut Suspensions Runner Purejet SUSP 110 ...

Page 111: ...ine Drill a 5 mm hole in the bracket so that the pin P can come out Fitting and caulking the kickstand pin to the bracket Caulk the end of the pin P between the two punches shown in the figure After caulking it must be possible for the stand to turn freely N B UPON REFITTING USE NEW O RING AND PIN GREASE THE SPRING ATTACHMENTS AND THE PIN Replacing full kickstand Loosen the three screws shown in t...

Page 112: ...INDEX OF TOPICS PURE JET INJECTION INJ PJ ...

Page 113: ...nd gas valve position in relation to preset mapping The fuel injection circuit consists of Fuel filter Pump feeding duct with auto bleeding Fuel pump Fuel injector Pressure regulator The injector mounting is connected by two snap on pipes The continuous circulation prevents the fuel from boiling The pressure regulator is placed in output of the injector mounting The fuel pump is controlled by the ...

Page 114: ...ht indicates the presence of a fault that usually requires the engine be stopped If the engine is functional slow down and proceed as quickly as possible with the necessary checks precautionary measures 1 Before fixing any part of the injection system check any registered faults Never disconnect the battery before checking for faults 2 The power supply system is pressurised at 250 800 KPa 2 5 8 BA...

Page 115: ...sealing ring 15 Do not perform voltage checks on the spark plug when it is not fitted on the head Power supply voltages are very high Hazard of dangerous electric shock In addition the air fuel mixture leaking from the spark plug may cause fire 16 Do not switch to ON during repair procedures when the tank is empty While on the road do not use the reserve if it could deplete the fuel 17 Do not disc...

Page 116: ...e instruments may damage the ECU The preferred instruments have a definition of more than 0 1V and 0 5 Ohm precision must be more than 2 autodiagnosis Self diagnosis The injection system is provided with a self diagnostic function The system recognises faults by analysing and comparing electric signals This recognises a missing signal and an unexpected signal Depending on the case the ECU can use ...

Page 117: ...nostic of the PUREJET injection system Specific tooling 020460Y Scooter diagnosis and tester The diagnostic tester is provided with a base setting menu To select the various functions proceed as follows 1 Press ESC and OK and keep them pressed while enabling the battery power 2 The display shows the following menu ECU DIAGNOSTIC LINK TO PC CONTRAST SET LAN GUAGE SET BUZZER SET VERSION 3 Select ECU...

Page 118: ...NTLY IMPAIR THE DI AGNOSTIC TESTER N B IF THE VEHICLE BATTERY IS USED THERE IS NO NEED TO ATTACH THE BLACK TERMINAL TO THE NEGATIVE TERMINAL ON THE BATTERY To disconnect the tester remove the terminals from the battery Remove the connector from the diagnostic outlet Reapply the protection cap to the diagnostic outlet to prevent dirt from depositing on the contacts Refit the battery cover All the p...

Page 119: ...NST CONS L H Indicates instantaneous fuel consumption D CYCLE CONS Indicates the ratio in between the time in ON and the time in OFF of the consumption meter control indicator this vehi cle is not fitted with this instrument ENGINE STATUS Displays the status of the engine STALL stopped CRANK start up IDLE minimum RUN gear ORC limit on revolutions in progress RUNNING HOURS Displays the engine runni...

Page 120: ...matic transmission or the clutch has required an excess driving force The fault is registered when the en gine management is not as expected for 3 con secutive times Light off G50 P0251 Fuel injector The ECU has detected an interruption in the injec tor circuit The fault can only be recognised in the presence of phase rpm Light on G50 P0350 H V coil The ECU has detected an interruption in the HV c...

Page 121: ...urs at the end of the period of use N B THE FAULT CAN BE SIGNALLED IN A SINGLE MODE THAT IS THE CURRENT AND STORED CONDITIONS CANNOT COEXIST Parameters stored This function displays the parameters stored previously As already specified in the description of the parameter function parameters are stored by pressing the TAB key at the selected time The diagnostic tester can contain a single memorisat...

Page 122: ... the vehicle CONSUMPTION GAUGE Instrument not present on the vehicle When the various diagnostics are enabled the tester displays its results ENDED SUCCESSFULLY or FAILED The tester results must always be combined with sound or visual checks The tester can confirm transmission of the command but cannot check the actual power supply or efficiency of the circuit under testing Resetting the TPS This ...

Page 123: ...Desc Quantity 1 Temperature sensor 2 WARNING light 3 HV coil 4 N 2 15 A fuses 5 Diagnostic socket 6 EMS electronic injection control unit 7 Throttle body 8 Coolant temperature sensor 9 Fuel injector 10 fuel pump Runner Purejet pure jet injection INJ PJ 123 ...

Page 124: ...ive 5 Coolant temperature indicator button negative 6 7 TPS 1 signal 8 9 Coolant temperature sensor positive 10 TPS 2 signal 11 12 H V coil negative 13 Air injector negative 14 Fuel pump negative 15 ECU power supply 12V 16 Coolant sensor and TPS sensor ground 17 Power supply 12V 18 TPS sensor positive 5V pure jet injection Runner Purejet INJ PJ 124 ...

Page 125: ...tity 1 Voltage regulator 2 Flywheel magneto pick up 3 ECU 4 Fuel injector 5 Water temperature sensor 6 Throttle body pos 7 Resistor 27 Ohm x 0 5W 8 Diagnostic light 9 Water temp indicator 10 Fuel pump 11 7 5A 12 Air injector 13 H V coil 14 Key switch contacts 15 Fuse 15A 16 Fuse 15A 17 Battery 18 Diagnostics outlet Runner Purejet pure jet injection INJ PJ 125 ...

Page 126: ... magneto 1 Turn the key switch to the ON position Check the following conditions Ignition light on steady Fuel pump activated for approx 4 5 seconds YES point 2 NO point 3 NO point 4 NO point 6 NO point 14 2 The ECU supplies are currently present GO TO point 9 N B WHEN THE SWITCH IS ON ON ALL SERVICES ARE ACTIVATED IF THERE ARE ANY FAULTS REFER TO SECTION VEHICLE ELECTRICS 3 The ignition light is ...

Page 127: ...ults relating to the battery voltage GO TO point 10 9 Connect the diagnostic tester of the scooter Select the errors function Check faults relating to bat tery voltage in stored status YES point 15 NO point 16 Specific tooling 020460Y Scooter diagnosis and tester 10 Measure the battery voltage GO TO point 11 GO TO point 12 11 Voltage is lower than 8 5 V Recharge the battery GO TO point 15 12 The b...

Page 128: ... not connecting the ECU Re connect the two 15 A fuses This toll mounted this way allows all checks on the installation sections GO TO point 21 Specific tooling 020481Y Control unit interface wiring 21 Check on the ground connection Check the ground connection on pin n 1 by using the multimeter 1 battery positive battery voltage YES point 22 NO point 23 22 The ground line is efficient GO TO point 2...

Page 129: ... 15 supply line 1 15 Ohm infinite YES point 31NO point 30 30 Restore the wiring insulation GO TO point 29 31 Connect the specific tool to the ECU Mount a new 20A fuse Check the presence of battery volt age between pin 15 and pin 1 the fuse does not burn 1 15 V battery YES point 33 NO point 32 32 The fuse is again burnt Check the wiring more accurately and if necessary replace the ECU GO TO point 3...

Page 130: ... the wiring from fuse holder to pin 17 GO TO point 34 40 If connections are conform and the fuse is burnt proceed as follows Disconnect the specific tool from the ECU Remove the 2 7 5 A fuses Remove the connector of the fuel pump GO TO point 41 Specific tooling 020481Y Control unit interface wiring 41 Remove the burnt 15A fuse Check the mass insulation of the supply line of pin 17 with the switch ...

Page 131: ...s check any possible short circuits or absorbance on the supply circuit of the fuel pump GO TO point 34 diagnosis tester connection circuit COMPONENTS LAYOUT 1 ECU 2 Diagnostic outlet A Under panel B Fixed Connect the scooter diagnostic tester Enter the main menu and select a function If the diagnostic tester returns ECU not responding check connections proceed as follows Specific tooling 020460Y ...

Page 132: ...ic connector Pin 2 Battery negative continuity YES point 7 NO point 6 6 Restore the continuity of the ground line 7 Connect the interface wiring Do not connect the wiring with the ECU Check the continuity of the line between the diagnostic con nector and ECU Pin 3 diagnostic connector Pin 21 continuity YES point 9 NO point 8 Specific tooling 020481Y Control unit interface wiring 8 Restore the wiri...

Page 133: ...iagnostic tester and the ECU if necessary Injection lamp circuit THERMIC 1 4 CONDITIONS Key selector set to ON engine off STANDARD Less than 0 1 V THERMIC 1 4 CONDITIONS Key selector set to ON engine on no fault detected STANDARD Battery voltage 1 ECU 2 Injection indicator Runner Purejet pure jet injection INJ PJ 133 ...

Page 134: ... The indicator lamp normally on will turn off for a moment thereby confirming the ECU operation The self diagnosis indicator function is also active on the injection indicator circuit Specific tooling 020460Y Scooter diagnosis and tester 1 Connect the scooter diagnostic tester Select the errors function Check the presence of error P0650 CHECK LAMP YES point 3 NO point 2 Specific tooling 020460Y Sc...

Page 135: ... electrical connectors Check the presence of volt age between white lead and black lead Black 5 5 White 6 8 battery voltage with switch to ON SI punto 10 NO point 9 9 Positive power to panel missing This comes from the switch and the 7 5A fuse Power supply is shared by the fuel level indicator and other uses Restore the wiring continuity GO TO point 8 10 Check the instrument panel injection lamp Y...

Page 136: ...iring See also autodiagnosis throttle position sensor circuit T P S TERMINALS 16 18 CONDITIONS Key switch set to ON STANDARD VALUES 5V TERMINALS 16 7 CONDITIONS Key switch set to ON opening the gas gradually STANDARD VALUES V progressive increase TERMINALS 16 10 CONDITIONS Key switch set to ON opening the gas gradually STANDARD VALUES V progressive decrease pure jet injection Runner Purejet INJ PJ...

Page 137: ...g increase The two signals will therefore be equivalent in a single point corresponding to mean opening 50 The two signals are converted into a percentage value of open ing of the gas valve The dual track system allows a greater control since signals TPS1 and TPS2 are compared to each other and to a reference map When TPS signals missing or not matching what expected are detected the auto diagnost...

Page 138: ... at this value the signals TPS1 and TPS2 are equal or very close a few hundreds volts difference N B FOR A MORE PRECISE CHECK PROGRESSIVELY OPEN THE VALVE DIRECTLY BY THE THROTTLE BODY USING A FLEXIBLE TRANSMISSION CAUSES AN IRREGULAR OPENING TPS1 ZERO V TPS2 ZERO V TPS TO REST NO YES The TPS signal reset function is used when signals TPS are efficient Select the errors function Check the followin...

Page 139: ...d The fault is recognised by com paring the signals with the TPS2 power supply polarity Free Off P1560 SENSOR VOLTAGE The TPS sensor and coolant tempera ture sensor power supply voltage do not meet specs Off P1561 VOLTAGES SENSOR 2 The TPS sensor and temperature sen sor power supply voltage does not meet specs Too high voltages may be rec ognised Forced idle On If one or more errors are detected o...

Page 140: ...g positive insulation N B THE CHECK SHOULD BE PERFORMED WITH THE BATTERY CONNECTED KEY SWITCH SET TO ON AND EFFICIENT FUSES 1 16 0 Volt 1 7 0 Volt 1 10 0 Volt 1 18 0 Volt YES point 8 NO point 7 7 Restore or replace the wiring GO TO point 6 8 Check the reciprocal insulation of the TPS sen sor connection lines 16 7 10 18 Reciprocal insulation 1 MW Check the connector efficiency YES point 10 NO point...

Page 141: ...stall or direction reversal The sum of voltages TPS1 and TPS2 must be constant and with values slightly lower than the TPS sensor power supply voltage YES point 16 NO point 15 15 Check the TPS and ECU connectors and replace the throttle body if required Replacement Resetting GO TO point 14 16 Check that the voltage values of signals TPS1 and TPS2 measured match those shown by the diagnostic tester...

Page 142: ...s occurs by resetting the signals TPS1 and TPS2 i e by reporting the voltage values TPS1 and TPS2 corresponding to the pre calibration position to the ECU These voltage values will be recognised as suitable by the ECU only if falling within the design default ranges The throttle body pre calibration register is sealed with paint and must not be tampered with The signals TPS1 and TPS2 may be reset ...

Page 143: ...OUTPUT V 0 64 TPS2 OUTPUT V 4 27 TPS1 ZERO V 0 64 TPS2 ZERO V 0 72 The voltage reported here corresponds to a possible condition GO TO point 6 6 Check the following conditions TPS1 OUTPUT TPS1 ZERO TPS2 OUTPUT TPS2 ZERO 5V YES point 7 NO point 8 7 The TPS reset meets specs 8 Repeat the reset procedure using the manual mode Specific tooling 020460Y Scooter diagnosis and tester Manual T P S reset MA...

Page 144: ...point 6 5 Check the auto diagnostic content and make the necessary repairs GO TO point 1 6 TPS reset in process Wait GO TO point 7 7 Key OFF Press a key GO TO point 8 8 Check the abut of the throttle body Push OK to proceed GO TO point 9 9 Wait GO TO point 10 10 Key on ON Press a key GO TO point 11 11 Wait GO TO point 12 12 Check for possible errors Wait GO TO point 13 13 No errors Press a key GO ...

Page 145: ...sor circuit TERMINALS 19 20 CONDITIONS Engine driven by the starter 500 600 RPM STANDARD VALUES V 3 5 4 TERMINALS 19 20 CONDITIONS Idle engine STANDARD VALUES V 11 12 COMPONENTS LAYOUT 1 Injection ECU 2 Pick up 3 to panel 4 fixed This integrated ignition and injection system requires a prompt perception of the running speed and of the crankshaft angular position The ECU must control the following ...

Page 146: ...he ECU self diagnostic checks the phase rpm signal even though the activity is limited to the rec ognition of any signal irregularities in an engine cycle In these cases ignition losses may occur and be signalled to the driver by a steady light A sharp interruption of the signal causes the engine to shut down and the fault is not perceived by the self diagnostic system When the phase rpm signal is...

Page 147: ... the ECU to the flywheel connector 19 red lead Ohm continuity 20 brown lead Ohm continuity YES point 7 NO point 6 6 If continuity is not detected restore or replace the wiring GO TO point 5 7 Check the ground insulation of the lines 1 19 1MOhm 1 20 1MOhm YES point 9 NO point 8 Runner Purejet pure jet injection INJ PJ 147 ...

Page 148: ...line positive insulation 1 19 0V 1 20 0V YES point 13 NO point 12 N B THE CHECK SHOULD BE PERFORMED WITH THE BAT TERY CONNECTED KEY SWITCH SET TO ON AND EF FICIENT FUSES 12 Restore the insulation or replace the wiring GO TO point 11 13 Connect the flywheel connector and repeat the insulation checks from earth and from positive 1 19 1MOhm 1 20 1 MOhm YES point 15 NO point 14 pure jet injection Runn...

Page 149: ... voltage produced by the phase rpm sensor with engine driven by the starter 19 20 3 5 4 V at 500 600 RPM YES point 19 NO point 18 18 Check the magnetic activity and gap of the phase rpm sensor Replace the stator if required GO TO point 17 19 Connect the interface wiring to the ECU Check the alternated voltage upon start up and at idle 19 20 3 5 4 V start up 19 20 11 12 V idle YES point 21 NO point...

Page 150: ...oil 6 Key switch 7 12V 9Ah Battery A under panel B Al magnet flywheel The injection system integrated with the inhection is inductive Ignition is managed based on two pa rameters Ignition advance Core dwelling time DWELL The ignition advance curve is optimised in function of the engine rpm and load perceived through the signals TPS1 and TPS2 pure jet injection Runner Purejet INJ PJ 150 ...

Page 151: ...ise produced by the magnetic activity and from the spark on the plug If this check is not possible use an external spark plug and check the 5 sparks directly YES point 3 NO point 4 NO point 5 3 There are 5 sparks The ignition system is working For greater certainty continue with the auto diagnostic check in order to highlight stored errors 4 No sparks present even if the result is test successful ...

Page 152: ...in any position 1 blue cable positive battery voltage YES point 4 NO point 3 N B TO MAKE THIS CHECK USE A SMALL SOCKET PAY AT TENTION NOT TO DAMAGE THE CONNECTOR 3 Check the efficiency of the 15A fuse If neces sary restore the wiring See ECU supply on page 5 41 GO TO punto 2 4 Check the continuity of the control line of the coil 12 violet black continuity YES point 6 NO point 5 N B TO MAKE THIS CH...

Page 153: ...ifferent resistances are detected replace the H V coil GO TO point 10 12 Check the ground insulation of the primary wir ing To make this check measure the resistance between one of the primary poles and the bar sup porting the coil to the frame Standard value 1MOhm YES point 14 NO point 13 13 If lower values are detected replace the H V coil GO TO point 12 14 Check the resistance of the screened c...

Page 154: ...50V peak YES point 18 NO point 19 N B USE THE ADAPTER WITH THE POSITIVE PROD ON PIN 12 IF THE ENGINE DOES NOT START CHECK THE INDUCED VOLTAGE AT THE START UP Specific tooling 020331Y Digital multimeter 020409Y Multimeter adaptor Peak voltage de tection 18 The system is efficient check timing 19 If the detected voltage is much lower than the minimum allowable check the core dwelling time reported i...

Page 155: ...ark plug and the original cap Con nect the induction clips of the stroboscopic lamp to the screened cable of the adapter according to their polarity Select the lamp control to the con ventional engine 2T position 1 spark 1 rev With engine idle set a degree phasing on the lamp equal to the indication of the advance shown in the tester parameters Check that the fifth to last tooth in the direction o...

Page 156: ...n the system To perform pneumatic inspections on the compressed air system proceed as follows 1 Remove the air supply duct of the injectors and install the air pressure control kit GO TO point 2 N B BE VERY CAREFUL WHEN CLEANING THE PARTS AND MAKING THE PROPER CONNECTION OF UNIONS ANY IMPURITY MAY DAMAGE THE AIR INJECTOR AVOID REMOVING THE RUB BER HOSE FROM THE BRASS HOSE HOLDERS IF REQUIRED REPLA...

Page 157: ...or GO TO point 3 8 Pressure decreases very quickly Check if there are any fuel leaks from the injector mounting YES point 9 YES point 10 NO point 11 9 There are leaks at the coupling to the head Re place the O Ring between air injector and support GO TO point 3 10 There are leaks at the pressure regulator cov er Replace the full injector mounting GO TO point 3 11 Use water with soap or foam to che...

Page 158: ...njector Use the diagnostic tester to remove the faults registered during pressure check GO TO point 17 Specific tooling 020460Y Scooter diagnosis and tester 17 Start the engine and check the air pressure with engine idle and free from loads at medium rpm Standard air pressure 5 5 5 bar 500 550 Kpa N B AIR PRESSURE DURING THE ENGINE OPERATION IS FAIRLY CONSTANT SINCE THE IN CREASE OF CAPACITY OF TH...

Page 159: ...ining better results with reference to polluting emissions and consumption The ECU self diagnosis also checks the air injector circuit Faults are recognised in case of circuit interruption or short circuit to earth and to positive Any fault is reported to the driver by the solid lighting of the injection indicator light In case of fault the engine cannot operate The fault is only recogtnised when ...

Page 160: ...er diagnostic tester Select the errors function Check the presence of error P1160 AIR INJECTOR GO TO point 7 YES point 8 YES point 9 Specific tooling 020460Y Scooter diagnosis and tester 7 No error present The injector electrics are efficient Check the compressed air circuit to inspect the injector seal 8 Air injector error in current status Check the air injector circuit 9 Air injector error in s...

Page 161: ...DO NOT INSERT THE PRODS INTO THE PINS 14 Restore the wiring GO TO point 13 15 Check the air injector control line positive in sulation 1 13 0V YES point 17 NO point 16 16 Restore the wiring GO TO point 15 17 Check the air injector control line negative in sulation 1 13 or 1MOhm YES point 19 NO point 18 18 Restore the wiring TO GO point 17 19 Check the air injector winding resistance standard value...

Page 162: ...f the switch YES point 25 NO point 24 Specific tooling 020481Y Control unit interface wiring 24 Voltage is close to 0V and the injector is open Carefully check the control line insulation Replace the ECU if required 25 The air injector control circuit is efficient The air injector opening time can be checked when the engine is running by the parameters menu AIR INJECTION T mS 6 7 mS start up at 20...

Page 163: ...less than 0 1 V TERMINALS 1 14 CONDITIONS Switch in ON position after timing with engine still STANDARD VALUES Battery voltage COMPONENTS LAYOUT 1 ECU 2 Injection indicator 3 Fuses 7 5A 4 Key switch 5 Fuel pump 6 Fuses 15A 7 Battery 12V 9Ah A To services B Fixed Runner Purejet pure jet injection INJ PJ 163 ...

Page 164: ...eed with the auto diagnostic and control circuit checks 3 Check whether the pump activation starts up again when trying to start the engine YES point 4 NO point 5 4 The pump control circuit is efficient 5 Check the auto diagnostic and the phase rpm signal 6 Connect the scooter diagnostic tester Select the active diagnostic function GO TO point 7 Specific tooling 020460Y Scooter diagnosis and teste...

Page 165: ...n with the ECU Disconnect the fuel pump supply connector GO TO point 16 Specific tooling 020481Y Control unit interface wiring 16 Turn the switch to the ON position Check for the presence of positive battery voltage at the orange pump supply connector wire 1 ORANGE battery voltage NO point 17 GO TO point 18 N B AVOID DAMAGING THE CONNECTOR PIN USE A PIN ADAPTOR IF NECESSARY 17 Check the efficiency...

Page 166: ...ding continuity Standard resistance Ohm 5Ohm measured N B IF THE CHECK IS DONE ON A NEW PUMP HIGHER RESISTANCE VALUES MIGHT RESULT DUE TO THE FACT THAT THE MANIFOLD HAS NOT BEEN BROKEN IN If there are difficulties in doing the check directly on the pump proceed with the check through the wiring Reconnect the fuel pump connector and measure the resistance between the specific tool s pins keeping th...

Page 167: ...he pump several times in order to distinguish any faults deriving from a manifold that is not perfectly effi cient GO TO point 29 GO TO point 30 29 Some pauses are present Check the connectors more carefully and replace the pump if necessary 30 The pump rotates normally The pump connection electric system is efficient Connect the ECU and check that the pump activates for around 4 seconds each time...

Page 168: ...ways very important in all the motor function phases but particularly during idling speed and start up The ECU auto diagnosis also check the petrol injector control circuit The anomaly is recognised in the case or circuit interruption or a short circuit both towards the earth and the positive Any anomaly is indicated to the driver through the fixed ignition of the injection warning light With the ...

Page 169: ...or circuit 6 Connect the scooter diagnostic tester Select the errors function on the menu Check the presence of any errors PO251 FUEL INJECTOR YES point 8 YES point 9 NO point 7 Specific tooling 020460Y Scooter diagnosis and tester 7 No error present The injector electric part is sufficient Proceed with the injector hydraulic inspections 8 Fuel injector error in current status Check the fuel injec...

Page 170: ...PRODS DO NOT INSERT THE PRODS INTO THE PINS 5 Restore the wiring GO TO point 4 6 Check the fuel injector control line positive in sulation 1 3 OV NO point 7 YES point 8 7 Restore the wiring GO TO point 6 8 Check the fuel injector control line negative in sulation 1 3 or 1Ohm NO point 9 YES point 10 9 Restore the wiring GO TO point 8 10 Check the fuel injector winding resistance Standard value Ohm ...

Page 171: ...d the injector is open Check the control line insulation Replace the ECU if necessary Specific tooling 020481Y Control unit interface wiring 16 The fuel injector control circuit is efficient While the engine is running the opening time of the fuel injector can be displayed through the indication given in the PARAMETERS menu of the scooter diagnostic tester T FUEL INJECTION mS about 6 mS start up a...

Page 172: ... the clamps part no CM001905 fixing the L shaped fitting to the pump are tightened correctly see picture 3 ensure there are no other faults or leaks due to deformations or abrasions to the connection hose 4 replace the fuel pump DIAGRAM OF FUEL SUPPLY SYSTEM Specification Desc Quantity 1 Fuel filter 2 Shunt 3 Fuel supply pump 4 Injector 5 Pressure regulator 6 Compressed air inlet 7 Fuel level 8 Ta...

Page 173: ...jected is only a function of the variations in ignition timing The supply circuit continues through the return duct from the injector mounting to the tank The attachment to the injector mounting is always of the quick fit type As this section of the circuit is downstream the pressure regulator it will constantly be at ambient pressure The fittings to the injector mounting are identified by the fol...

Page 174: ...ltage over 12V activate the fuel pump by turning the key switch onto ON GO TO point 5 N B BEFORE INSTALLATION CAREFULLY BLOW THE DUCTS OF THE SPECIAL TOOL ANY IMPURITY MAY DAMAGE THE FUEL INJECTOR DETACH AND REATTACH THE QUICK FIT FITTINGS AS PRESCRIBED Specific tooling 020331Y Digital multimeter 020481Y Control unit interface wiring 5 Let the system bleed for a few seconds and check the following...

Page 175: ...ow specs The pump rotates with too low a torque and the flow rate is reduced Replace the pump GO TO point 5 11 The pressure regulator requires a pressure below specs Replace the injector mounting assembly with the pressure regulator GO TO point 5 12 Using flat ended pliers gradually shut the spe cial tool hose on the injector mounting side With battery voltage above 12V check the follow ing Fuel p...

Page 176: ...essary If necessary check the tank flow rate GO TO point 14 N B WHEN THE FUEL FILTER IS VERY DIRTY AIR MAY BE SUCKED THROUGH THE BLEED DUCT THIS CAN DAMAGE THE FUEL PUMP 16 Detach the special tool ammeter Reattach the ECU connector Reattach the return duct to the tank Start the engine and check the following condi tions Injection air pressure 5 5 5 BAR Fuel pressure 7 5 8 BAR NO point 17 NO point ...

Page 177: ... of the compressed air system 22 The air pressure remains constant The fuel pressure decreases rapidly Bring the pressure back up into the system by starting the engine Shut down the engine and at the same time close the rubber hose on the injector mounting side us ing flat ended pliers Check that the fuel pressure remains constant NO point 23 YES point 24 Specific tooling 020616Y Fuel pressure co...

Page 178: ...th of fuel line connect the outlet fitting to the tank Install the interface wiring omitting the ECU at tachment Jump pins 14 1 and activate the pump by turning the key switch onto ON Let the system bleed and ensure the injector is leak free Max allowed oozes no drip before 15 sec onds NO point 27 YES point 28 27 If leaks are found from the injector or its O Ring these should have been spotted dur...

Page 179: ...point 30 29 If not to spec flow rates are found replace the injector mounting assembly 30 The fuel injector is in working order coolant temperature sensor circuit COMPONENTS LAYOUT 1 ECU 2 Resistor 27 Ohm 0 5W 3 Coolant temperature indicator 4 Injection indicator 5 Fuses 7 5A 6 Key switch 7 Fuse 15A 8 Battery 12V 9Ah A To the services Runner Purejet pure jet injection INJ PJ 179 ...

Page 180: ...B Fixed pure jet injection Runner Purejet INJ PJ 180 ...

Page 181: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 182: ... the oil in an appropriate container Loosen the two support calliper clamps Refitting On refitting work in the reverse order and respect the indicated torques Locking torques N m Rear brake calliper 20 25 Nm Front brake calliper Braking system Runner Purejet BRAK SYS 182 ...

Page 183: ...place the entire calliper CAUTION ALL THE INTERNAL COMPONENTS MUST BE REPLACED EVERY TIME THE CALLIPER IS SERVICED Refitting Insert in the calliper body sealing rings 1 2 small pistons 3 place the OR seal in a calliper body 4 Join the internal and external body with the as sembly bolts Refit pads and bleed air see pre ceding paragraphs Position the calliper on the disc and lock to the mounting by ...

Page 184: ...to exit from its housing de tach the spring which blocks the hydraulic line under the transmission protection crankcase Rectify the split pin remove the plastic cover and unscrew the wheel axle nut keeping the disc blocked Loosen the five clamps and remove the disc Refitting On refitting perform the operations in reverse order applying the recommended threadblock to the five disc clamps Tighten th...

Page 185: ...y LOCTITE medium type 242 threadlock Locking torques N m Disc tightening screw 6 7 N m Disc Inspection Remove the wheel and check any out of level of the disc using the specific tool The measurement revealed must be within 0 1 mm If the measurement is greater replace the disc and repeat the test If the problem continues check and if necessary replace the wheel rim Specific tooling 020335Y Magnetic...

Page 186: ...he system to the maximum level with brake fluid Loosen the bleed valve Apply the tube of the specific tool to the bleed valve To bleed the circuit you must supply the reservoir constantly with oil while pumping the Mityvac pump until there is no more air leaving the circuit The operation is concluded when the bleed screw delivers only oil and no air Close the bleed screws When you have finished th...

Page 187: ...RY TWO YEARS IF THE BRAKES ARE USED INTENSELY AND OR IN HARSH CONDITIONS CHANGE THE FLUID MORE FREQUENTLY CAUTION 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 DE GREASE THE DISC SHOULD THERE BE OIL ON IT Specific tooling 020329Y MityVac vacuum operated pump Recommended products AGIP BRAKE 4 Brake fluid...

Page 188: ... remove the wheel cylin der 1 Tank cap screw 2 Tank cover 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8 Spring CAUTION THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAK ING EFFICIENCY IN THIS CASE REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH QUALITY SOL VENT CONTACT WITH BRAKE FLUID WILL DAMAGE PAINTED SURFACES RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LON...

Page 189: ... in denatured alcohol before proceeding Reinstall the individual parts in the reverse order to the removal paying attention to the correct po sitioning of the rubber parts in order to ensure leak tightness 1 Tank cap screw 2 Tank cover 3 Diaphragm 4 Bellows 5 Sealing ring 6 Piston 7 Gasket 8 Spring Runner Purejet Braking system BRAK SYS 189 ...

Page 190: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 191: ...PAY ATTENTION NOT TO OVERLOAD THE PLASTIC IMPELLER Specific tooling 020620Y Water pump impeller stop Remove the mixer water pump drive belt with the two crown wheels Remove the snap ring of the pump bearing stay Remove the steel washer Using the air heater warm up the crankcase in the area around the water pump bearings as shown in the picture Runner Purejet Cooling system COOL SYS 191 ...

Page 192: ...the special hook remove the sealing ring from its housing as shown in the picture Specific tooling 020209Y Spring hook Ensure the shaft is not abnormally worn and the bearings not noisy Otherwise replace shaft and bearings Carefully clean oil seal and bearing housings Use a new oil seal to refit Position the new oil seal on the special tool with the main lip facing the bearings as shown in the pic...

Page 193: ...oap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 Insert the shaft with bearings into its housing by pushing and turning it at the same turn anticlock wise for tightening Turn it rapidly to the end of the threading Should this operation prove difficult do not carry on instead start over by reheating the crankcase N B FAILURE TO OBSERVE THIS RULE MAY RESULT IN DAM AGE TO THE THREAD OF TH...

Page 194: ...ge the multimeter temperature probe and keep it close to the thermostat Heat up the bowl using the thermal gun Check the thermostat opening start temperature Heat up until the thermostat is completely open 3 Replace the thermostat if not working properly CAUTION TO EXECUTE THE TEST CORRECTLY MAKE SURE NEI THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER Specific tooling 020331Y Digita...

Page 195: ...the thermostat onto the head fol lowing the removal operations in the reverse order and paying attention in inserting the groove on the thermostat on the reference on the head Runner Purejet Cooling system COOL SYS 195 ...

Page 196: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 197: ... Rear rack Remove the side fairings Remove the three screws shown in the picture See also Side fairings Rear handlebar cover Remove the three screws disconnect the elec trical connections and the odometer transmission Runner Purejet Chassis CHAS 197 ...

Page 198: ...light assy Remove the front grill Remove the three screws shown in the picture and disconnect the electrical connections See also Legshield Frame central cover Remove the front shield Loosen the three screws shown in the picture Remove the fuel expansion chamber plugs and finally detach the cable for opening the refueling chamber To remove the cover raise the rear part first See also Legshield Cha...

Page 199: ...ight assy Remove the screw shown in the figure and re move the grill pulling it upward and then out Removing the ignition key switch when on off Remove central cover Insert a small centre punch through the hole shown by the arrow in the figure and push until the retaining tooth on the master cylinder is released whilst keep the punch pressed against the tooth extract the lock body and master cylin...

Page 200: ...cing down halfway on the lock body taking care that the insertion phase of the key is oriented matching ON the only position that enables the cylinder to get into the lock body now turn the key leftwards to OFF and at the same time press until the cylinder is completely in See also Legshield Footrest Remove the side Remove the two screws and loosen the joints very carefully See also Side fairings ...

Page 201: ...he picture See also Side fairings Remove the rear grille Remove the air conveyor To remove the side panel remove the two rear screws the screw on the rim of the seat the screw located near the conveyor the two screws located on the footrest the screw located under the footrest and the screw to connect with the front panel Runner Purejet Chassis CHAS 201 ...

Page 202: ...de the battery compartment Remove the 4 screws shown in the picture on the front part of the helmet compartment Remove the 2 screws indicated in the picture on the rear part of the helmet compartment See also Seat Side fairings spoiler Rear spoiler Remove the 2 built in hexagonal head screws Chassis Runner Purejet CHAS 202 ...

Page 203: ...trical con nections being careful not to let gasoline spill out See also Frame central cover Rear central cover Rear closure element Remove the rear spoiler Loosen the two screws and remove the element See also spoiler Front mudguard Loosen the four screws fixing the fender to the fork Runner Purejet Chassis CHAS 203 ...

Page 204: ...ooled down com pletely to avo id serious burns before removing it On refitting use the specific pliers for the clips Specific tooling 020544y Pliers for clamps See also Frame central cover Expansion tank Remove the front shield Unscrew the two screws shown in the picture and remove the piping CAUTION DO NOT ALLOW THE COOLANT TO DRIP Chassis Runner Purejet CHAS 204 ...

Page 205: ...the oil pump from the tank See also Helmet bay Front central cover Remove the two screws indicated in the picture Lower cover To remove this element it is necessary to remove the Fork removal Loosen the three screws shown in the picture and also remove the screw which fixes the air duct for the cooling transmission See also Removal Runner Purejet Chassis CHAS 205 ...

Page 206: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 207: ...ORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE WARNING BEFORE RECHARGING THE BATTERY REMOVE THE CAPS OF EACH CELL KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED REMOVE THE BATTERY FROM THE SCOOTER DISCONNECTING THE NEGATIVE TERMINAL FIRST CAUTION WHEN INSTALLING T...

Page 208: ... DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Check levels Brake fluid level Oil change level Oil mix level Road test Cold start Speedometer check Throttle check Riding stability Front and rear brake efficiency Front and rear shock absorbers Unusual noises Hot engine restart Leakages after trial run Static test Tyre pressure Operation of all locks Fitting mirrors and accessories Equipment ...

Page 209: ...Functional inspection Brake lever excursion Throttle excursion and adjustment Homogeneous steering turning Runner Purejet Pre delivery PRE DE 209 ...

Page 210: ...INDEX OF TOPICS TIME TIME ...

Page 211: ...INE Code Action Duration 1 001001 Eng from frame Removal and refit 2 003057 Engine retainer Tighten nuts Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replacement Runner Purejet Time TIME 211 ...

Page 212: ...RANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001118 Bench bearings Replacement 3 001099 Oil seal flywheel side Replacement 4 001100 Oil seal clutch side Replacement Time Runner Purejet TIME 212 ...

Page 213: ...Cylinder assy PISTON CYLINDER TEST PROBE ASSEMBLY Code Action Duration 1 001002 Cylinder Piston Replacement 2 001107 Cylinder piston Service clean Runner Purejet Time TIME 213 ...

Page 214: ...Cylinder head assy INLET MANIFOLD HEAD Code Action Duration 1 001056 Head gasket Replacement 2 001013 Inlet manifold Replacement 3 003056 Head cylinder Nuts tightening Time Runner Purejet TIME 214 ...

Page 215: ...ement 3 001057 Thermostat Replacement 4 007010 Bleed valve Replacement 5 005110 Fuel injector mounting Replace ment 6 005111 Air injector Replacement 7 005112 Air injector Service 8 001061 O Ring tube coolant delivery Re placement 9 001083 Thermistor Replacement Runner Purejet Time TIME 215 ...

Page 216: ...N PULLEY Code Action Duration 1 001110 Driven pulley Replacement 2 001012 Driven pulley Service 3 001022 Clutch Replacement 4 003072 Clutch assembly Check wear 5 001155 Clutch bell Replacement Time Runner Purejet TIME 216 ...

Page 217: ...Oil pump OIL PUMP Code Action Duration 1 001019 Mixer belt Replacement 2 001028 Mix gear movement Replacement 3 001018 Mixer Replacement Runner Purejet Time TIME 217 ...

Page 218: ...ey DRIVING PULLEY Code Action Duration 1 001086 Driving half pulley replace 2 001066 Driving pulley Removal and refit 3 001066 Driving pulley Service 4 001011 rear view belt Replacement Time Runner Purejet TIME 218 ...

Page 219: ...NSMISSION COVER FEMALE SCREW Code Action Duration 1 001096 Transmission crankcase cover Re placement 2 001135 Transmission cover bearing Re placement 3 001131 Transmission air intake Replace ment Runner Purejet Time TIME 219 ...

Page 220: ...Water pump WATER PUMP Code Action Duration 1 001113 Water pump Replacement 2 001062 Pump command shaft Removal and refit Time Runner Purejet TIME 220 ...

Page 221: ...Starter motor STARTER Code Action Duration 1 001017 Starter pinion Replacement 2 001020 Starter motor change 3 005045 Starter cable assembly Replace ment Runner Purejet Time TIME 221 ...

Page 222: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001087 Flywheel cover Replacement 2 001058 Flywheel Replacement 3 001067 Stator Removal and refit Time Runner Purejet TIME 222 ...

Page 223: ...Belt cooling duct BELT REFRIGERATION TUBE Code Action Duration 1 001132 Transmission air intake pipe Re placement 2 001131 Transmission air intake Replace ment Runner Purejet Time TIME 223 ...

Page 224: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Time Runner Purejet TIME 224 ...

Page 225: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement Runner Purejet Time TIME 225 ...

Page 226: ...LEANER Code Action Duration 1 001014 Air filter Replacement 2 001015 Air filter box Replacement 3 001027 Bodywork cleaner union Replace ment 4 004122 Cleaner Throttle body union Re placement Time Runner Purejet TIME 226 ...

Page 227: ...Frame KICKSTAND FRAME Code Action Duration 1 004001 Frame Replacement 2 006001 Frame Painting 3 004004 Kickstand Replacement 4 001053 Stand bolt Replacement Runner Purejet Time TIME 227 ...

Page 228: ... FAIRING Code Action Duration 1 004085 Fairing 1 Replacement 2 004012 Rear fairings Removal and refitting 3 004059 Spark plug inspection flap Replace ment 4 006008 Rear side panel Replacement Time Runner Purejet TIME 228 ...

Page 229: ...Rear cover LOWER SHIELD FAIRING Code Action Duration 1 004022 Shield lower section Replacement Runner Purejet Time TIME 229 ...

Page 230: ...L FAIRING Code Action Duration 1 004011 Central chassis cover Replacement 2 004068 Passenger handgrip Replacement 3 004056 Upper rear light cover Replacement 4 006040 Passenger handle Paintwork Time Runner Purejet TIME 230 ...

Page 231: ...CENTRAL FAIRING Code Action Duration 1 004132 Semishield Paintwork 2 004133 Semishields Replacement 3 006039 Semishield Replacement Mudguard Runner Purejet Time TIME 231 ...

Page 232: ...ment 2 004002 Front mudguard Replacement 3 006003 Mudguard Painting Fuel tank FUEL TANK Code Action Duration 1 004005 Fuel tank Replacement 2 004109 Fuel tank breather Replacement 3 004110 Fuel tank hose Replacement 4 005010 Tank float Replacement Time Runner Purejet TIME 232 ...

Page 233: ...MIXER DEGASSER Code Action Duration 1 004017 Oil reservoir Replacement 2 004095 Oil reservoir cock Replacement 3 005018 Oil reservoir float Replacement 4 004091 Oil reservoir hose Replacement Runner Purejet Time TIME 233 ...

Page 234: ...Expansion tank EXPANSION TANK Code Action Duration 1 007001 Expansion tank Replacement Time Runner Purejet TIME 234 ...

Page 235: ...Radiator RADIATOR Code Action Duration 1 007002 Water cooling radiator Replace ment 2 007003 Coolant delivery and return pipe Re placement 3 001052 Coolant Replacement Runner Purejet Time TIME 235 ...

Page 236: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Removal and refit Time Runner Purejet TIME 236 ...

Page 237: ...arings STEERING THRUST WASHER Code Action Duration 1 004119 Bearing upper steering fifth wheel Replacement 2 003002 Steering thrust washer Replace ment 3 003073 Steering clearance Adjustment Runner Purejet Time TIME 237 ...

Page 238: ...ration 1 005014 Odometer Replacement 2 005038 Instrument panel warning light bulbs Replacement 3 004018 Handlebar front section Replace ment 4 004019 Handlebar rear section Replace ment 5 006013 Front part of handlebar Paintwork Time Runner Purejet TIME 238 ...

Page 239: ...g system Re placement 2 002067 Rear brake pump Replacement 3 002020 Rear brake pipes Removal and re fitting 4 002037 Brake or clutch lever Replacement 5 002071 Left hand grip Replacement HANDLEBAR COMPONENTS Code Action Duration 1 004066 Rear view mirror Replacement Runner Purejet Time TIME 239 ...

Page 240: ...ump Removal and Re fitting 7 002018 Front brake pump Service 8 005017 Stop switch Replacement Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame swinging arm attach ment Replacement We inform you that in order to avoid the possibility of a contact between the helmet bay and the injector fitting swing arm no 560522 has been replaced by part no 599286 Seat Time Runner Purejet TIME 240...

Page 241: ... 004003 Saddle Replacement Turn signal lights OPTICAL UNIT Code Action Duration 1 005008 Front headlamp bulbs Replacement 2 005002 Front light Replacement 3 005044 Front lights cable unit Replacement Runner Purejet Time TIME 241 ...

Page 242: ... Replace ment BACK HEADLIGHT Code Action Duration 1 005066 Rear light bulbs Replacement 2 005005 Tail light Replacement 3 005028 Rear light assembly glass Replace ment 4 005022 Rear turn indicators Replacement 5 005068 Rear turn indicator bulb Replace ment 6 005048 Licence plate holder Replacement Time Runner Purejet TIME 242 ...

Page 243: ...im Removal and refit 7 003040 Front wheel bearings 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 lyb...

Page 244: ...l REAR WHEEL Code Action Duration 1 001016 Rear wheel Replacement 2 004126 Rear wheel tyre Replacement 3 001071 Rear wheel rim Removal and refit 4 003063 Tyre pressure Check 5 006018 Wheel rim Paintwork 6 002070 Rear brake disc Replacement 7 002028 Rear wheel hub Replacement Time Runner Purejet TIME 244 ...

Page 245: ...compressore aria AIR COMPRESSOR Code Action Duration 1 001168 Air compressor Replacement 2 004160 Compressed air hose Replacement Runner Purejet Time TIME 245 ...

Page 246: ...mp SUPPLY SYSTEM Code Action Duration 1 004072 Fuel filter Replacement 2 004073 Fuel pump Replacement 3 004137 Injector pump pipe Replacement 4 004138 Fuel reverse pipe Replacement Time Runner Purejet TIME 246 ...

Page 247: ...tion Duration 1 005113 Plug with contacts Replacement 2 005069 Left switch Replacement 3 005040 Horn button Replacement 4 005003 Horn Replacement 5 005041 Starter button Replacement 6 005039 Headlight switch Replacement Runner Purejet Time TIME 247 ...

Page 248: ...placement 3 004010 Anti theft lock Replacement ELECTRIC DEVICES Code Action Duration 1 001069 HV coil Replacement 2 001094 Spark plug cap Replacement 3 001023 Control unit Replacement 4 005001 Electrical system Removal and re fitting 5 005009 Voltage regulator Replacement Time Runner Purejet TIME 248 ...

Page 249: ...BATTERY ELECTRIC DEVICES Code Action Duration 1 005052 Fuse Replacement 2 005011 Start up remote control switch Re placement 3 005025 Fuse holder Replacement Runner Purejet Time TIME 249 ...

Page 250: ...te odometer transmission Replacement 2 002063 Complete gas command trans Re placement 3 002054 Complete gas command or splitter trans Replacement 4 002057 Splitter transmission complete throttle body Replacement 5 002058 Splitter transm compl mix Re placement 6 002012 Splitter Replacement 7 002049 Odometer wire Replacement Time Runner Purejet TIME 250 ...

Page 251: ... 1 002039 Front brake calliper Removal and refit 2 002040 Front brake calliper Check 3 002021 Front brake line Removal and refit 4 002047 Frt brake fluid and bleeding circuit Replacement 5 003070 Front brake pads Shoes Check wear Runner Purejet Time TIME 251 ...

Page 252: ... 003071 Rear brake pads Wear check 2 002002 Rear brake pads Replacement 3 002068 Rear brake calliper Check 4 002048 Rear brake calliper Replacement 5 002081 Rear brake disc piping Replace ment Fuel tank filler flap Time Runner Purejet TIME 252 ...

Page 253: ...ion 1 004135 Fuel tank lid Replacement 2 002082 Fuel tank cap opening drive Re placement Helmet bay HELMET HOLDER Code Action Duration 1 004016 Helmet compartment Removal and refit 2 004054 Seat lock hook Replacement Runner Purejet Time TIME 253 ...

Page 254: ...Rear wheel axle REAR WHEEL AXLE Code Action Duration 1 001010 Reduction gear Service 2 003065 Gear box oil Replacement 3 004145 Rear wheel axle Replacement Time Runner Purejet TIME 254 ...

Page 255: ... Code Action Duration 1 003051 Complete fork Replacement 2 003041 Fork stanchion Replacement 3 003048 Oil seal fork Replacement 4 003039 Fork leg mandrels Replacement 5 003010 Front suspension Service Runner Purejet Time TIME 255 ...

Page 256: ...Cooling system COOLING SYSTEM Code Action Duration 1 007009 Head pump by pass rubber coupling Replacement Time Runner Purejet TIME 256 ...

Page 257: ...1 C Control panel Coolant 172 179 F Fuel 32 163 203 232 246 252 H Headlight 34 198 199 Horn Hub oil 30 I Identification 6 M Maintenance 6 27 O Odometer S Shock absorbers 110 Spark plug 29 T Tank 203 205 232 234 252 Transmission 7 36 62 219 Turn indicators Tyres 8 ...

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Summary of Contents for Runner Purejet 2007

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Gilera Runner Purejet 2007, Workshop Manual, Page: 191 / 257

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Summary of Contents for Runner Purejet 2007

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