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Product

Description

Specifications

AGIP CITY HI TEC 4T

Oil for flexible transmission lubri-
cation (acceleration control, mix-

er and odometer)

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-

based spray grease with NLGI 2;

ISO-L-XBCIB2

AGIP CITY TEC 2T

Mixer oil

synthetic oil for 2-stroke engines:

JASO FC, ISO-L-EGD

AGIP GREASE MU3

Grease for odometer transmis-

sion gear case

Soap-based lithium grease with

NLGI 3; ISO-L-XBCHA3, DIN

K3K-20

AGIP BRAKE 4

Brake fluid

FMVSS DOT4 Synthetic fluid

AGIP GREASE SM 2

Grease for compensating ring

NLGI 2; ISO-L-XBCHB2, DIN

KF2K-20 Molybdenum disul-

phide grease and lithium soap

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 2; ISO-L-

XBCIB2

AGIP PERMANENT PLUS

Coolant

Monoethylene glycol antifreeze

fluid, CUNA NC 956-16

AGIP GREASE SM 2

Greasing the driven pulley bush-

ing

Soap-based lithium grease with

NLGI 2 Molybdenum Disulphide;

ISO-L-XBCHB2, DIN KF2K-20

Runner RST Purejet

Characteristics

CHAR - 11

Summary of Contents for Runner RST Purejet

Page 1: ...MANUALE STAZIONE DI SERVIZIO 633600 633607 Runner RST Purejet ...

Page 2: ...make any changes 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 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 Repro...

Page 3: ...ispone degli impianti e delle attrezzature necessarie ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici 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 spe...

Page 4: ......

Page 5: ...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 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 8: ... 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 removal...

Page 9: ... 104 Engine idle 2000 g min Air filter sponge impregnated in fuel mixture fuel 50 oil Starting system electric starter Lubrication By oil leakage through pump with flow rate varying according to the engine speed and throttle open ing Fuel supply Air assisted direct fuel injection into the combus tion chamber The electric pump is controlled by the injection ECU Inlet By means of a compression valve...

Page 10: ...h 5 Fuses One 20A battery two 5A batteries 6 Generator In star three phase alternating current Frame and suspensions FRAME Specification Desc Quantity Chassis type Welded tubular steel chassis with stamped sheet reinforcements Front suspension Hydraulic fork with upside down rods Front fork stroke 73 mm Front stroke 66 mm Rear suspension single hydraulic shock absorber coaxial helical spring Frame...

Page 11: ...llic spacers 4 M5 Ø 8 8 steel screw on brass copper aluminium and their alloys 4 M5 Ø 8 8 steel screw Iron steel 6 M6 Ø 8 8 steel screw on plastic with metallic spacers 6 5 M6 Ø 8 8 steel screw on brass copper aluminium and their alloys 6 5 M6 Ø 8 8 steel screw Iron steel 10 5 M7 Ø 8 8 steel screw on brass copper aluminium and their alloys 10 5 M7 Ø 8 8 steel screw Iron steel 17 M8 Ø 8 8 steel scr...

Page 12: ...E Name Torque in Nm Calliper tightening screw 20 25 Brake fluid tube calliper 13 18 Brake fluid pump hose fitting 13 to 18 Nm Disc tightening screw 6 6 5 Rear wheel axle 100 125 Rear wheel hub screw 20 25 Oil bleed screw 7 to 10 Nm N B IN ORDER TO ENSURE AN ADEQUATE LOCKING TORQUE LUBRICATE THE NUTS BEFORE ASSEMBLING THEM ENGINE ASSEMBLY Name Torque in Nm Head tightening nut 10 11 Coolant bleed sc...

Page 13: ...ER PISTON FITTING Name Initials Cylinder Piston Play on fitting Cylinder M 39 997 40 004 39 943 39 95 0 047 0 061 Cylinder N 40 004 40 011 39 95 39 957 0 047 0 061 Piston O 40 011 40 018 39 957 39 964 0 047 0 061 Piston P 40 018 40 025 39 964 39 971 0 047 0 061 Cylinder 1st over M1 40 197 40 204 40 143 40 15 0 047 0 061 Cylinder 1st over N1 40 204 40 211 40 15 40 157 0 047 0 061 Piston 1st over O1...

Page 14: ...Dimensions Initials Quantity Connecting rod 11 75 0 0 05 A 0 25 0 50 Shoulder washer 0 5 0 03 G 0 25 0 50 Semi shaft trans side 13 75 0 04 0 C 0 25 0 50 Semi shaft fly wheel side 13 75 0 04 0 D 0 25 0 50 Spacer tool 40 64 H 0 25 0 50 Casing 11 8 0 0 35 B 0 20 0 75 Shoulder washer 0 5 0 03 G 0 20 0 75 Semi shaft trans side 13 75 0 04 0 C 0 20 0 75 Semi shaft fly wheel side 13 75 0 04 0 D 0 20 0 75 ...

Page 15: ...rod Ø 17 0 011 0 001 G 0 002 0 012 Roller casing 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 Descrip tion Dimens ions Initials Quantit y 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 Roller casing Cat 1 Ø 2 5 0 0 002 Roller casing Cat 2 Ø 2 5 0 002...

Page 16: ...o the stud bolts keeping to the torque wrench setting and take the piston to the dead centre position The thickness of the gasket to fit will change de pending on the value found Three gaskets are given with the following thick ness Specific tooling 020272Y Piston position check tool Locking torques N m Locking head nuts 10 11 N m SHIMMING SYSTEM Name Measure A Thickness Shimming 2 80 3 04 0 4 Shi...

Page 17: ...D AGIP GREASE MU3 Grease for odometer transmis sion gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid AGIP GREASE SM 2 Grease for compensating ring NLGI 2 ISO L XBCHB2 DIN KF2K 20 Molybdenum disul phide grease and lithium soap AGIP GREASE PV2 Grease for control levers on the engine White anhydrous calcium based grease to pro...

Page 18: ...Characteristics Runner RST Purejet CHAR 12 ...

Page 19: ...INDEX OF TOPICS TOOLING TOOL ...

Page 20: ...liers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm ø bear ings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract ø 15 mm bear ings 001467Y014 Pliers to extract ø 15 mm bear ings Tooling Runner RST Purejet TOOL 2 ...

Page 21: ...1467Y017 Bell for bearings outside Ø 39 mm 001467Y021 Extraction pliers for ø 11 mm bearings 001467Y029 Bell for bearings O D 38 mm 002465Y Pliers for circlips 004499Y Camshaft bearing extractor Runner RST Purejet Tooling TOOL 3 ...

Page 22: ...eel seat on steering tube 020004Y Punch for removing fifth wheels from headstock 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crank shaft alignment 020080Y Punch for removing 12 mm bear ings 020150Y Air heater support Tooling Runner RST Purejet TOOL 4 ...

Page 23: ...0151Y Air heater 020162Y Flywheel extractor 020163Y Crankcase splitting plate 020164Y Driven pulley assembly sheath 020166Y Pin lock fitting tool 020168Y Water seal punch mount on half crankcase Runner RST Purejet Tooling TOOL 5 ...

Page 24: ...9Y Water pump crankshaft fitting and removal spanner 020170Y Water pump mixer command gear extractor 020171Y Punch for driven pulley roller bearing 020209Y Spring hook 020265Y Bearing fitting base Tooling Runner RST Purejet TOOL 6 ...

Page 25: ...ption 020272Y Piston position check tool 020325Y Brake shoe spring calliper 020329Y MityVac vacuum operated pump 020330Y Stroboscopic light for timing con trol 020331Y Digital multimeter Runner RST Purejet Tooling TOOL 7 ...

Page 26: ...34Y Multiple battery charger 020335Y Magnetic 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 Tooling Runner RST Purejet TOOL 8 ...

Page 27: ...cription 020363Y 20 mm guide 020409Y Multimeter adaptor Peak volt age detection 020376Y Adaptor handle 020412Y 15 mm guide 020439Y 17 mm guide 020444Y Test probe removal fitting tool Runner RST Purejet Tooling TOOL 9 ...

Page 28: ...020456Y Ø 24 mm adaptor 020451Y Start up crown lock 020452Y Tube for removing and refitting the driven pulley shaft 020460Y Scooter diagnosis and tester 020481Y Control unit interface wiring Tooling Runner RST Purejet TOOL 10 ...

Page 29: ...liper spanner 020469Y Reprogramming kit for scooter diagnosis tester 020614Y Diagnostic tester programming software 020615Y Carbon dam ring fitting kit 020616Y Fuel pressure control kit 020617Y Air pressure check kit Runner RST Purejet Tooling TOOL 11 ...

Page 30: ...Stores code Description 020620Y Water pump impeller stop 020621Y HV cable extraction adaptor Tooling Runner RST Purejet TOOL 12 ...

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

Page 32: ...sing Brake pads check condition and wear Brake fluid level check Coolant level check Electrics Check Tyre pressure and wear check Vehicle and brake test road test AT 10 000 KM 50 000 KM Action Hub oil level Check Replace Spark plug replacement Fuel filter replacement Air filter clean Oil mixer throttle linkage adjustment Variator rollers Check wear Steering adjustment Brake control levers greasing...

Page 33: ...lean 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 and wear check Vehicle and brake test road test ...

Page 34: ...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 Disconnect the lug of the spark plug and remove it Examine it carefully and if the insulation coating is splintered or damaged replace...

Page 35: ...he bottom 4 Screw the dipstick back into place complete ly The screw B is the hub oil drainage tap CAUTION USING THE ENGINE WITH INSUFFICIENT LU BRICATION OR WITH THE WRONG LUBRI CANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY CAUSE SERI OUS DAMAGE CAUTION USED OILS CONTAIN SUBSTANCES HARM FUL TO THE ENVIRONMENT FOR OIL RE PLACEMENT CONTACT AN AUTHORISED SERVICE CENTRE WHICH IS EQUIPP...

Page 36: ...oil CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCES SIVE 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 Fuel filter To access the fuel filter remove the cover of the central tunnel and the left mat Remove the filter using the clamping strap...

Page 37: ...Y HI TEC 4T Oil for flexible transmis sion lubrication acceleration control mixer and odometer Synthetic oil that passes SAE 5W 40 API SL ACEA A3 JASO MA specifications Grease the ends of the cable Transmission adjustment Set the command cables Mix cable see the following procedure Mixer Timing Gas cable adjust so there is no play in the sheathes Splitter command cable adjust so there is no play i...

Page 38: ...L STARTS TO FLOW TIGHTEN THE SCREW START THE ENGINE AND WAIT FOR OIL TO COME OUT FROM THE DELIVERY TUBE TO THE CARBURETTOR ALREADY DISCONNECTED Reconnect the delivery tube to the carburettor and secure it with the appropriate clamp When doing this step pour a small amount of the recommended product into the intake or in the blade holder Recommended products AGIP CITY TEC 2T Mixer oil synthetic oil...

Page 39: ... and check that the bor derline of the projected light beam on the screen is not lower than 9 10 of the distance from the ground to the centre of vehicle headlamp and high er 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 REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS REFER TO T...

Page 40: ...Maintenance Runner RST Purejet MAIN 10 ...

Page 41: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 42: ...FAULTY CLUTCH Possible Cause Operation 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 WARNI...

Page 43: ...The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance Frequently check that the fluid level fully covers the plates otherwise re store 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 nee...

Page 44: ...ue in turning the steering even after making the above adjustments check the seats in which the ball bearings rotate replace if they are recessed Noisy suspension NOISY SUSPENSION Possible Cause Operation Noisy suspension If the front suspension is noisy check the efficien cy of the front suspension the condition of the ball bearings and relevant lock nuts the limit switch rubber stoppers and the ...

Page 45: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 46: ...r 6 Air injector 7 Key switch 8 Fuse box Fuse 1 General 20A Fuse 2 Horn and indicators 5A Fuse 3 Lights 5A 9 Battery 10 Starter 11 Remote control ignition 12 Ignition button 13 STOP button on rear brake 14 STOP button on front brake 15 Horn 16 Horn button Electrical system Runner RST Purejet ELE SYS 2 ...

Page 47: ...nit A Parking light B High beam headlight C Low beam headlight 23 Right front direction indicator light 24 Light switch 25 Turn indicator switch 26 Oil control indicator light 27 Fuel level transmitter 28 Instruments unit 29 Water temperature probe 30 Fuel pump 31 Phonic wheel 32 Position sensor of throttle body 33 Outlet for diagnostics 34 Electronic central unit Conceptual diagrams Runner RST Pu...

Page 48: ...wheel 2 Voltage regulator 3 Spark plug 4 high voltage coil 7 Key switch 8 Fuse box Fuse 1 General 20A Fuse 2 Horn and indicators 5A Fuse 3 Lights 5A 9 Battery 34 Electronic central unit Electrical system Runner RST Purejet ELE SYS 4 ...

Page 49: ...eneral 20A Fuse 2 Horn and indicators 5A Fuse 3 Lights 5A 9 Battery 19 Rear optical unit A Parking light B Stop light 22 Front optical unit A Parking light B High beam headlight C Low beam headlight 24 Light switch 28 Instruments unit Runner RST Purejet Electrical system ELE SYS 5 ...

Page 50: ...x Fuse 1 General 20A Fuse 2 Horn and indicators 5A Fuse 3 Lights 5A 9 Battery 10 Starter 11 Remote control ignition 12 Ignition button 13 STOP button on rear brake 14 STOP button on front brake 19 Rear optical unit A Parking light B Stop light 26 Oil control indicator light Electrical system Runner RST Purejet ELE SYS 6 ...

Page 51: ... 8 Fuse box Fuse 1 General 20A Fuse 2 Horn and indicators 5A Fuse 3 Lights 5A 9 Battery 26 Oil control light 27 Fuel level transmitter 28 Instruments unit 29 Water temperature probe 30 Fuel pump 31 Phonic wheel 32 Position sensor of throttle body 33 Outlet for diagnostics Runner RST Purejet Electrical system ELE SYS 7 ...

Page 52: ...Fuse 3 Lights 5A 9 Battery 15 Horn 16 Horn button 17 Intermittence device for turn indicators 18 Left rear direction indicator light 20 Right rear direction indicator light 21 Left front direction indicator light 23 Right front direction indicator light 25 Turn indicators switch 28 Instruments unit Electrical system Runner RST Purejet ELE SYS 8 ...

Page 53: ... Specification Desc Quantity 1 Battery 2 permanent power supply 3 Ground lead 4 Grounding for phonic wheel 5 Power supply to phonic wheel 6 Phonic wheel signal 7 Instrument lighting 8 enabling temperature instrument Runner RST Purejet Electrical system ELE SYS 9 ...

Page 54: ...tor is connected directly to the ground and the battery positive passing through the 20A protection fuse Therefore this system does not have any connection to the key switch The three phase generator provides good recharge power at low rpm it represents a good compromise between distributed power and idle stability Stator check Disconnect the connector from the voltage regu lator and check for con...

Page 55: ... 12 volts Start the engine and measure the current distrib uted by the circuit with the lights on and engine at high rpm If the current value is less than 10A repeat the test using a new regulator and or stator instead Starter motor Specifications Rated voltage 12V Rated power 0 25 kW Left rotation viewed from pinion side Connection to engine with pinion and crown wheel on transmission side cranks...

Page 56: ...s battery nega tive and starter negative are correctly connected to each other and to the frame Connect the diagnostic tester Connect an ammeter induction clamp to the neg ative power supply cable 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...

Page 57: ...INK cable for the left lights level indicators Made up of a fuel level transmitter digital reading instrument and a fuel reserve light If problems occur check The fuel reserve light Make sure that the WHITE wire of the instrument unit is under a voltage of 12V with the key switch at ON Using the multimeter the ohm values of the fuel level transmitter moving the arm with the floater Limit values em...

Page 58: ...GING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF REACH OF CHILDREN Characteristic Battery 12V 9Ah Commissioning dry charge batteries 1 Once the short closed tube and caps are removed add sulphuric acid to the elements of a type for batteries with a specific gravity of 1 26 corresponding to 30 Bé at a temperature of at least 15 C until reaching the uppe...

Page 59: ...simeter see figure CHECKING ELECTROLYTE DENSITY Specification Desc Quantity Keep the tube vertical Check with bare eye The float must be released When the battery is charged the density should be 30 32 Bé corresponding to a specific weight of 1 26 1 28 at a temperature not under 15 C If the density falls below 20 Bé the battery is completely run down and needs to be recharged When a battery is bei...

Page 60: ... Single battery charger 020334Y Multiple battery charger 4 Cleaning the battery The battery should always be kept clean especially the upper part and the terminals protected with vaseline CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE CAUTION IN EMERGENCIES THE CHARGING TIME CAN BE...

Page 61: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 62: ...ake 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 Engine from vehicle Runner RST Purejet ENG VE 2 ...

Page 63: ... 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 Runner RST Purejet Engine from vehicle ENG VE 3 ...

Page 64: ...om the fuel and air injector Remove the electric connector from the throttle body Remove the fastening of the wiring clamp to the thermostat clamp by removing the screw indicated in photo Engine from vehicle Runner RST Purejet ENG VE 4 ...

Page 65: ...g the special hole 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 coolant temperature sensor con nector Runner RST Purejet Engine from vehicle ENG VE 5 ...

Page 66: ...perature sensor Carefully clean the connectors removing any dirt and foreign material Respect the clamps of the fuel lines to the engine Make sure that the fuel line connectors are perfectly 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 APPROX ...

Page 67: ...INDEX OF TOPICS ENGINE ENG ...

Page 68: ...aging 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 DIAMETER 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 REFI...

Page 69: ...lutch 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 screw...

Page 70: ...erial 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 Pin ...

Page 71: ...TION PLIERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING Specific tooling 001467Y029 Bell for bearings O D 38 mm Remove the ball bearing retention snap ring Expel the ball bearing from the side of the clutch housing by means of the special tool N B PROPERLY SUPPORT THE HALF PULLEY SO AS NOT TO DEFORM THE SLIDING SURFACE OF THE DRIVING BELT Specific tooling 020376Y Adaptor handle 02...

Page 72: ... the driven sliding half pulley Remove the 2 inner sealing rings and the two O rings Measure the inside diameter of the mobile half pulley bushing Characteristic Mobile driven half pulley Maximum diameter allowed Ø 34 08 mm Check the belt contact surfaces Insert the new oil seal and O rings on the mobile half pulley Fitting the half pulley on the bushing Recommended products AGIP GREASE SM 2 Greas...

Page 73: ...NT DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Refitting the driven pulley Check the surfaces contacting with the belt Insert 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 DRIVE...

Page 74: ...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 SOCKET WRENCH WITH SMALL CHAMFER CAUTION POSITION THE NON C...

Page 75: ...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 76: ...ck Inspecting the rollers case 1 Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation 2 Check the roller running tracks on the contact pulley there must not be signs of wear and check the condition of the contact surface of the belt on the half pulleys mobile and stationary 3 Check that the rollers do not show signs of marked facetting on th...

Page 77: ...driven half pulley away pulling it towards the clutch unit and insert the belt repeating the direction of rotation of the first fitting N B IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO THE WORDING CAN BE READ IN THE CASE THAT THIS DOES NOT SHOW A FITTING SIDE Reassemble the unit parts roller housing unit with bushing washer stationary half pulley belt cooling fan with intake washer and nut N B RE...

Page 78: ...tting the clutch Removing the wheel axle Remove the intermediate gear and the complete gear wheel axle When removing the intermediate gear pay atten tion to the various shim adjustments Removing the wheel axle bearings Remove the oil seal and the seeger ring Remove the bearing by pushing from the outside towards the inside of the gear compartment using the appropriate punch Specific tooling 020363...

Page 79: ...pecial tube on the internal raceway of the bearing and from the shaft toothed side as indicated in the figure Expel the driven pulley shaft with the aid of a press Specific tooling 020452Y Tube for removing and refitting the driven pulley shaft Inspecting the hub shaft Check that the three shafts exhibit no wear or deformation on the toothed surfaces at the bear ing housings and at the oil guards ...

Page 80: ...or radial part on the bearing side N B FIT THE BALL BEARING WITH THE SHIELD FACING THE OIL SEAL Specific tooling 020151Y Air heater 020376Y Adaptor handle 020439Y 17 mm guide 020358Y 37x40 mm adaptor Refitting the wheel axle bearing Heat the half crankcase on the transmission side using a thermal gun After lubricating its outer strip insert the bearing with the special adapter with the aid of a ha...

Page 81: ...n them to the pre scribed torque N B CLEAN THE CONTACT SURFACES OF THE HUB COVER AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BE FORE APPLYING A NEW ONE Locking torques N m Locking torque 11 to 13 Nm Flywheel cover Removing the stator Remove the flywheel cover Use a specific compass wrench and a 15 mm Allen wrench to remove the flywheel lock nut Specific tooling 020565Y Flywheel lock ca...

Page 82: ...volutions sensor to the coolant inlet pipe Remove the coolant inlet duct Remove the two stator fixing screws Remove the stator with wiring 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 Engine Runner RST Purejet ENG 16 ...

Page 83: ...et hose refit the flywheel cover paying attention in inserting the strap in the groove Tighten the 4 studs noting that 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 Runner RST Purejet Engine ENG 17 ...

Page 84: ...he fuel in jector and the pressure regulator using the 2 screws 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 INJEC TOR PLASTIC SUPPORT Engine Runner RST Purejet ENG 18 ...

Page 85: ...om the head with the relevant O ring using the two 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 Runner RST Purejet Engine ENG 19 ...

Page 86: ...SE PAPER OR A CLOTH TO CLOSE THE CYL INDER HOUSING MOUTH ON THE CRANK CASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE Remove the roller from the connecting rod as shown in the figure Remove the piston sealing rings CAUTION NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSI TION IN CASE OF REUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOV...

Page 87: ...d small end standard diameter 17 0 011 0 001 Rod small end maximum allowable diameter 17 060 mm Inspecting the wrist pin Check the wrist pin external diameter using a mi crometer Characteristic Wrist pin standard diameter 12 0 005 0 001 mm Inspecting the piston Measure the bearings on the piston using a bore meter Calculate the piston pin coupling clearance Characteristic Wrist pin housing standar...

Page 88: ...o measure the cylinder inside diameter according to the directions shown in the figure Check that the fitting surface with the head is not worn 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 ...

Page 89: ...cting rod with piston facing the outlet Insert the wrist pin stop ring in the specific 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 Runner RST Purejet Engine ENG 23 ...

Page 90: ...t the tool on the cylinder without changing the dial 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 cylinde...

Page 91: ...hem 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 a...

Page 92: ...fit 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 See ...

Page 93: ... 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 Speci...

Page 94: ...ase 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 BEARING Z...

Page 95: ...ide 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 A...

Page 96: ...il approx 1 l Gradually 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...

Page 97: ...urfaces of diam A B C are within 0 03 mm reading limit on the dial gauge in addition check the eccentricity of diam D for which a maximum reading of 0 02 mm is permitted In the case where eccentricity is not much above prescribed levels straighten the shaft by acting on the counterweights with a shim or tighten them in a clamp with an aluminium bushing as re quired Specific tooling 020335Y Magneti...

Page 98: ...ucts available on the market Avoid any method that may impair the crankcase fitting surfaces To facilitate this operation remove the rotor Please note that the threading is anticlockwise Check the fitting surfaces and the bearing and oil seal capacities Check the cleaning and efficiency of the unidir ectional valve of the oil supply to the pump case Check the correct installation of the reference ...

Page 99: ...ER FOLLOWING THE HEATING RULES AND BEING CAREFUL TO THE SHAFT INSER TION MOVEMENT DO NOT LUBRICATE THE SHAFT SINCE THE CRANKCASE HALF FIT TING SURFACES MAY BE SOILED Let the crankcase half temperature settle with the crankshaft temperature Install the specific crankcase separation plate again without installing the crankshaft guard Keep the central thrust screw loosened during assembly Move the 4 ...

Page 100: ...flywheel side crankcase half with a firm and precise move N B WEAR GLOVES WHEN HANDLING THE CRANKCASE HALF DO NOT USE RAGS FOR THIS OPERATION Insert at least 3 fixing screws and tighten quickly Insert 5 more screws and tighten at the prescribed torque Locking torques N m Crankcase closing screws 12 13 Nm Move the crankcase separation plate in a position back from the one indicated in the figure In...

Page 101: ...ssor Removal Removing air compressor Remove the throttle 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 RST Purejet Engine ENG 35 ...

Page 102: ... 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 RST Purejet ENG 36 ...

Page 103: ... 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 RST Purejet Engine ENG 37...

Page 104: ...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 En...

Page 105: ...r Refit the throttle body Refit the flywheel stator Refit the mixer Refit the driven pulley Refit the driving pulley Oil pump Refitting To refit perform the removal procedures in the reverse direction Perform purging after refitting using the screw shown in the figure Runner RST Purejet Engine ENG 39 ...

Page 106: ...Engine Runner RST Purejet ENG 40 ...

Page 107: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 108: ...nt wheel hub overhaul Remove the front wheel Keep the wheel level by means of two wooden wedges With the appropriate pliers and tool remove the wheel bearing on the side the rpm indicator detects movement as shown in the photograph Specific tooling 001467Y014 Pliers to extract ø 15 mm bearings 001467Y009 Driver for OD 42 mm bearings Suspensions Runner RST Purejet SUSP 2 ...

Page 109: ... a hot air gun heat the seat of the bearing on the brake calliper side With an appropriate tool remove the bearing on the brake disk side Insert the spacer bushing on the brake disk side Specific tooling 020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 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...

Page 110: ...Remove the wheel loosening the five clamps Refitting the rear wheel On refitting tighten to the prescribed torque in a cross over pattern Locking torques N m Rear wheel 20 25 Nm Shock absorbers Removal To replace the shock absorber simply remove the door to access the tool bag and remove the shock absorber chassis nut Then remove the shock absorber engine anchor bolt Suspensions Runner RST Purejet...

Page 111: ... from the en gine 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 complete kickstand Loosen the three...

Page 112: ...Stand screw torque 18 5 to 19 Nm Suspensions Runner RST Purejet SUSP 6 ...

Page 113: ...INDEX OF TOPICS PURE JET INJECTION INJ PJ ...

Page 114: ...d 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 E...

Page 115: ...t 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 BAR...

Page 116: ...ealing 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 disco...

Page 117: ... 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 b...

Page 118: ...r the diagnostic 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 ...

Page 119: ... minals to the diagnostic tester Connect the terminals to the battery respecting the polarity RED BLACK N B FAILURE TO DO SO MAY PERMANENTLY IM PAIR THE DIAGNOSTIC TESTER N B IF THE VEHICLE BATTERY IS USED THERE IS NO NEED TO ATTACH THE BLACK TERMINAL TO THE NEGATIVE TERMINAL ON THE BAT TERY To disconnect the tester remove the terminals from the battery Remove the connector from the diagnostic out...

Page 120: ... ground TPS2 RESET V Indicates the reset voltage of the TPS2 indicator voltage referring to the positive 5V VOLT BATT V Indicates the power supply voltage of the ECU normally identical to the power of the vehicle bat tery T OF DWELL MS Indicates the core dwell time of the H V coil MIN RPM Indicates the number of engine revolutions set in the ECU for checking the minimum INST CONS L H Indicates ins...

Page 121: ...igh Flashing light G30 P1560 voltage sensor The TPS sensor and coolant temperature sensor supply voltage are not as expected Light off G30 P1561 Sensor 2 TPS voltage sensor and coolant temperature sen sor are not as expected high temperature Engine remains at forced idle Light on G40 P0219 Runaway rpm The engine has reached excessive rpm Light on G40 P0335 Rpm pickup The ECU cannot properly recogn...

Page 122: ...ence of phase rpm Light on Faults are reported by a dark dot on one of the reference columns The recognition occurs in 3 modes Dot on the column marked A The fault is CURRENT and present during the check Dot on the column marked with O The letter denotes OCCURRED The fault has occurred and has been fixed during the same period of use The fault may be intermittent and not present dur ing the check ...

Page 123: ... for approx 30 seconds TEMPERATURE INDICATOR The indicator increases to display an average tem perature then returns to the rest position to per form with cold engine CHECK LAMP The light is normally on The diagnostic is con firmed when the light turns off briefly ODOMETER Instrument not present on the vehicle CONSUMPTION GAUGE Instrument not present on the vehicle When the various diagnostics are...

Page 124: ...2 To services 13 To flywheel 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 ELECTR...

Page 125: ... 8 In current mode the tester signals faults 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 Rech...

Page 126: ... to the vehicle installation omitting the ECU connection reconnect the 20A fuse This tool mounted as described checks all system 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 ...

Page 127: ... supply line 1 15 Ohm infinite YES point 31 NO 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 31 ...

Page 128: ...e continuity of the wiring from fuse holder to pin 17 GO TO point 34 40 If connections meet specs and the fuse is burnt proceed as follows Disconnect the specific tool from the ECU remove the two 5 A fuses remove the connector of the fuel pump GO TO point 41 Specific tooling 020481Y Control unit interface wiring 41 Remove 20 A burnt fuse Check the ground insulation of the power lines of pin 17 wit...

Page 129: ...o faults 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 0...

Page 130: ...c 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 wirin...

Page 131: ...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 Runner RST Purejet pure jet injection INJ PJ 19 ...

Page 132: ...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 diagnostic...

Page 133: ...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 following...

Page 134: ...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 or ...

Page 135: ... 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 136: ...all 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 i...

Page 137: ... 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 a...

Page 138: ...TPUT 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 MANU...

Page 139: ...int 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 TO...

Page 140: ...or 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 u...

Page 141: ...e 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 142: ...he 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 pure jet injection Runner RST Purejet INJ PJ 30 ...

Page 143: ...line positive insulation 1 19 0V 1 20 0V YES point 13 NO point 12 N B THE CHECK SHOULD BE PERFORMED WITH THE BATTERY CONNECTED KEY SWITCH SET TO ON AND EFFICIENT 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 Runner RST Purejet pure j...

Page 144: ...oltage 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 2...

Page 145: ... rameters Ignition advance Core dwelling time DWELL The ignition advance curve is optimised according to the engine rpm and load perceived through the TPS1 and TPS2 signals The core dwelling time is optimised according to the power required by the H V coil Naturally longer core dwelling times are used during start up phases The ECU auto diagnostic also checks the coil power supply circuit detectin...

Page 146: ...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 Continue with circuit checks If there are no faults replace the ECU GO TO point 2 5 No sparks present The result is test failed Repeat the diagnostic and if necessary replace the ECU G...

Page 147: ... point 4 NO point 3 N B TO MAKE THIS CHECK USE A SMALL SOCK ET PAY ATTENTION NOT TO DAMAGE THE CONNECTOR 3 Check the efficiency of the 20A fuse If neces sary restore the wiring GO TO point 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 CHECK USE A SMALL SOCK ET PAY ATTENTION NOT TO DAMAGE THE CONNECTOR 5 Restore the wirin...

Page 148: ...ferent 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 cap...

Page 149: ...0V 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 in...

Page 150: ...rk 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 of...

Page 151: ...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 152: ... 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 check...

Page 153: ...ector 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 THE ...

Page 154: ...he H V coil Naturally longer core dwelling times are used during start up phases The ECU auto diagnostic also checks the coil power supply circuit detecting interruptions or short circuits The check is only performed in the presence of rpm phase signals engine running Faults are indicated to the driver by the injection light lighted steady In addition to safeguard the safety of the vehicle the inj...

Page 155: ...he 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 stored status Check the circui...

Page 156: ...IN SERT 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 GO TO point 17 19 Check the air injector winding resistance standard value circa...

Page 157: ...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 C...

Page 158: ... pump 6 20A fuses 7 Battery 12V 9Ah A To the services B Fixed The fuel pump is a piston type supplied with a continuous current engine It was designed to supply high pressures with small capacities and low absorption and is therefore suitable for use on reduced capacity engines Given the low absorption the pump is directly supplied by the ECU without the use of remote control switches The pump is ...

Page 159: ... diagnostic function GO TO point 7 Specific tooling 020460Y Scooter diagnosis and tester 7 Check that the tank is adequately topped up and proceed with the activation of the fuel pump diagnostic Listen for 10 consecutive activations of around 4 seconds of the fuel pump Check the outcome on the diagnostic tester YES point 8 NO point 9 NO point 10 8 The fuel pump was activated 10 times and the teste...

Page 160: ... 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 of the 15A fuse and key switch If necessary restore the wiring GO TO point 16 18 Check the continuity of the control line of the fuel pump 14 green blue fuel pump ...

Page 161: ...resistance between the specific tool s pins keeping the switch in the OFF position 14 17 Ohm 5Ohm measured YES point 26 NO point 25 25 A resistance of around 0 Ohm indicates the presence of a short circuit A resistance signifi cantly greater than the standard values indicates low conductivity In these cases replace the pump GO TO point 24 26 Keeping the ECU conditions disconnected and pump connect...

Page 162: ...heck that the pump activates for around 4 seconds each time the switch is turned ON and constantly when the rpm phase engine in rotation signal is present Replace the ECU if there are any faults GO TO point 31 31 For a more complete fuel pump check it is best to proceed with the checks on the current absorbed and the hydraulic characteristics of the pump petrol injector circuit TERMINALS 1 3 CONDI...

Page 163: ...ctor diagnostic Listen for 5 fuel injector activations Check the diagnostic tester response YES point 3 NO point 4 NO point 5 3 The fuel injector was activated 5 times and the tester returned the test completed successfully outcome The fuel injector and the relative circuit are efficient For further certainty proceed with the auto diagnostic test in order to avoid any errors in the stored status 4...

Page 164: ...ER PRODS DO NOT IN SERT THE PRODS INTO THE PINS Specific tooling 020481Y Control unit interface wiring 3 Check the efficiency of fuse 15A and restore the wiring if necessary GO TO point 2 4 Check the continuity of the fuel injector control line 3 white continuity NO point 5 YES point 6 N B THIS CONNECTOR ALLOWS AN EASY CHECK USING THE MULTIMETER PRODS DO NOT IN SERT THE PRODS INTO THE PINS 5 Resto...

Page 165: ...injector winding negative insu lation 1 any pin of the injector or 10 Ohm NO point 13 YES point 14 13 Replace the air injector mounting GO TO point 12 14 Connect the specific tool to the ECU Connect the fuel injector connector Check the presence of voltage to the ECU 1 3 battery voltage engine off and any posi tion of the switch NO point 15 YES point 16 15 Voltage is close to 0V and the injector i...

Page 166: ...Fuel filter 2 Shunt 3 Fuel supply pump 4 Injector 5 Pressure regulator 6 Compressed air inlet 7 Fuel level 8 Tank ventilation The first section of the fuel supply system on the fuel injection version of the Runner consists of an outlet fitting located in the lower half of the tank Fuel flows through the transparent type paper filter and to the shunt just before the pump The shunt is attached to th...

Page 167: ...tantly be at ambient pressure The fittings to the injector mounting are identified by the following markings FI INLET FO OUTLET The circuit provides continuous fuel flow with the tank to guarantee the uninterrupted cooling and ven tilation of the injector mounting and therefore a more constant fuel preparation When refilling the system after maintenance or repair operations 10 11 pump cycles are r...

Page 168: ...LATION CAREFULLY BLOW THE DUCTS OF THE SPECIAL TOOL ANY IM PURITY MAY DAMAGE THE FUEL INJECTOR DETACH AND REATTACH THE QUICK FIT FIT TINGS 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 Fuel pressure 2 5 BAR Absorbed current 0 25 0 30 A NO point 6 NO point 9 NO point 7 YES point 12 6 P...

Page 169: ... 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 pre...

Page 170: ...ssary 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 1...

Page 171: ...f 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 cont...

Page 172: ...h 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 duri...

Page 173: ...l output from the injector standard distribution 14 cm3 pressure 2 5 BAR in 15 seconds NO point 29 YES point 30 29 If not to spec flow rates are found replace the injector mounting assembly 30 The fuel injector is in working order Runner RST Purejet pure jet injection INJ PJ 61 ...

Page 174: ...pure jet injection Runner RST Purejet INJ PJ 62 ...

Page 175: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 176: ...er Remove the clamps highlighted in the diagram On refitting tighten the bolts to the prescribed tor que Perform bleeding procedure on the system Overhaul Remove the calliper assembling bolts and take out the internal bodies and components If necessary in order to make it easier to take out the plungers inject shorts blasts of compressed air through the brake fluid pipe Check that the cylinders of...

Page 177: ...t be perfectly clean and free of traces of oil diesel fuel grease etc They should be washed thoroughly in denatured alcohol before proceeding The sealing rings must be immersed in the liq uid used the use of protective PRF1 is allowed CAUTION RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL FOR LONGER THAN 20 SECONDS AFTER WASHING THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN CLO...

Page 178: ...move the disc Refitting On refitting perform the operations in reverse order applying the recommended threadblock to the five disc clamps Tighten the disc screws to the prescribed torque in a crossover pattern Tighten the wheel axle nut to the prescribed torque Recommended products Loctite 242 product description Apply LOCTITE medium type 242 threadlock Locking torques N m Disc screws torque 6 6 5...

Page 179: ...e 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 support for dial gauge Front brake pads Removal Proceed as follows Remove the front calliper Loosen the two pins shown in the figure that lock the two pads Remove the pads being carefu...

Page 180: ...S OF BEING FAULTY LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS CAUTION DURING THE OPERATIONS THE VEHICLE MUST BE ON THE STAND AND LEVEL N B DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP WARNING BRAKING CIRCUIT FLUID IS HYGROSCOPIC IT ABSORBS HUMIDITY FROM THE SUR ROUNDING AIR IF THE LEVEL OF HUMIDITY IN THE BRAK...

Page 181: ...sconnect the tube collecting the brake oil in a container On refitting perform the operation in reverse Tighten the hydraulic lines to the prescribed tor que and bleed the circuit Locking torques N m Hydraulic line torque 13 18 N m Removal Bleed the circuit and drain the brake fluid through the bleeding screw located on the calliper and ac tuate the brake lever until no more fluid flows out Remove...

Page 182: ...MPRESSED AIR AND A CLEAN CLOTH THE SEALING RINGS MUST BE IMMERSED IN THE OPERATING LIQUID Refitting Before fitting the parts must be perfectly clean and free of traces of oil diesel fuel grease etc They should be washed thoroughly 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 part...

Page 183: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 184: ...Y ATTEN TION NOT TO OVERLOAD THE PLASTIC IM PELLER 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 Cooling system Runner RST Purejet COOL SYS 2 ...

Page 185: ...he 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 pict...

Page 186: ...p 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 RE SULT IN DAMAGE TO THE THREAD OF THE ...

Page 187: ...e 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 NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER Specific tooling 020331Y Digital ...

Page 188: ...he 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 Cooling system Runner RST Purejet COOL SYS 6 ...

Page 189: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 190: ...cting the wiring remove the rear handlebar See also Front handlebar cover Front handlebar cover Front handlebar cover Remove the rear view mirrors Remove the two screws shown in the figure and at the same time disconnect the fitting in the upper part of the handlebar cover Pull the front part up wards so as not to damage the fittings made of plastic Chassis Runner RST Purejet CHAS 2 ...

Page 191: ...he fittings made of plastic Headlight assy Remove the front shield Remove the 2 screws indicated in the photograph at the back of the shield then disconnect the wiring and remove the headlight assembly See also Legshield Frame central cover Remove the saddle and the two screws indicated in the photograph Remove the air ducts then operate the screw in dicated in photograph Runner RST Purejet Chassi...

Page 192: ...y pulling it upwards To fit repeat the procedure in reverse order being careful to replace the metal clamp of the fuel tank filling hole Legshield Remove the shield central cover Remove the 2 screws shown in the photograph Remove the 10 screws 5 per side indicated in the photograph Remove the 7 screws indicated in the photograph from the front wheel compartment Lever on the plastic parts creating ...

Page 193: ...d Remove the central chassis cover Remove the shield central cover and remove the supporting screws for the expansion tank Remove the 10 screws 5 per side of the shield back plate indicated in the photograph Remove the central screw A indicated in the photo then remove the shield back plate Follow the procedure in reverse order to refit See also Frame central cover Runner RST Purejet Chassis CHAS ...

Page 194: ...when on lock Remove the shield Remove the switch of the key switch Make a hole on the block using a drill as shown in the figure Insert the wheel cylinder with the key and with the anchoring tab facing down halfway on the lock body taking care that the insertion phase of the key is oriented matching ON the only position that enables the cylinder to get into the lock body now turn the key leftwards...

Page 195: ... well at the frame Disconnect the brake pipe to the pump and pull it out Remove the odometer transmission Taillight assy Remove the two screws and take out the whole unit Footrest Remove the 3 screws indicated in the figure and remove the footrest Runner RST Purejet Chassis CHAS 7 ...

Page 196: ... Fairing B Remove fairing A Remove the passenger handles Remove the rear light assembly Remove the license plate holder undoing the 4 screws indicated in the figure Remove the screw of the rear wheel compart ment Remove the 2 screws indicated in the figure Remove the screw located below the fairing A Pull out the fairing Chassis Runner RST Purejet CHAS 8 ...

Page 197: ... wiring found in the battery compart ment Disconnect the cable of the saddle opening de vice Remove the 5 screws indicated in the figure lo cated on the front part of the helmet compartment Remove the 2 screws indicated in the figure lo cated on the rear part of the helmet compartment Remove the screw indicated in the figure located on the rear wheel compartment and then remove the helmet compartm...

Page 198: ... the figure Lift the chassis very gently being careful with the cables affixed to it Disconnect the electrical connections and the fuel tank pipes when extracting the chassis N B this operation should be preferably be carried out with the tank empty See also Frame central cover Side fairings Helmet bay Front mudguard Loosen the four screws fixing the fender to the fork Chassis Runner RST Purejet C...

Page 199: ...hotograph Remove the cap momentarily to disconnect it from the shield back plate by pulling it downwards Disconnect the expansion tank from the support anchored to the chassis Prepare a container to collect the coolant Remove the coolant in top and return bottom pipes Assembly following the procedure in reverse or der See also Legshield Mixture oil tank Remove the helmet compartment Disconnect the...

Page 200: ...coperchio batteria installare la batteria rispettando le polarità come mostrato in foto Lower cover Remove the footrests Remove the 4 screws 2 per side indicated in the photograph of the front wheel compartment Remove the two bottom screws 1 per side of the shield back plate then lever the plastic parts to reach the screws A indicated in the photo graph Remove the lower cover Chassis Runner RST Pu...

Page 201: ...Runner RST Purejet Chassis CHAS 13 ...

Page 202: ...Chassis Runner RST Purejet CHAS 14 ...

Page 203: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 204: ...olt Engine Engine arm pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Fill the battery with battery acid charge it with a suitable charger Key switch Low beam lights high beam lights warning lights parking lights Headlight adjustment Rear light Stop light possibly front and rear brake Turn indicators and relevant warning lights L...

Page 205: ...5 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION THE BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT ...

Page 206: ...nce document CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST WARNING BE VERY CAREFUL WHEN HANDLING FUEL Functional inspection Brake lever excursion Regulating the gas control excursion Uniform steering rotation Pre delivery Runner RST Purejet PRE DE 4 ...

Page 207: ...INDEX OF TOPICS TIME TIME ...

Page 208: ...Engine ENGINE Code Action Duration 1 001001 Eng from frame Removal and refit 2 003057 Engine retainer Tighten nuts Time Runner RST Purejet TIME 2 ...

Page 209: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replace ment Runner RST Purejet Time TIME 3 ...

Page 210: ...NKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001118 Bench bearings Replace ment 3 001099 Oil seal flywheel side Re placement 4 001100 Oil seal clutch side Replace ment Time Runner RST Purejet TIME 4 ...

Page 211: ...Cylinder assy PISTON CYLINDER TEST PROBE ASSEMBLY Code Action Duration 1 001002 Cylinder Piston Replace ment 2 001107 Cylinder piston Service clean Runner RST Purejet Time TIME 5 ...

Page 212: ...rmostat Replacement 4 007010 Bleed valve Replacement 5 005110 Fuel injector mounting Re placement 6 005111 Air injector Replacement 7 005112 Air injector Service 8 001061 O Ring tube coolant delivery Replacement 9 001083 Thermistor Replacement 10 007009 Head pump by pass rubber coupling Replacement Time Runner RST Purejet TIME 6 ...

Page 213: ...INLET MANIFOLD HEAD Code Action Duration 1 001056 Head gasket Replacement 2 001013 Inlet manifold Replacement 3 003056 Head cylinder Nuts tighten ing Runner RST Purejet Time TIME 7 ...

Page 214: ... 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 RST Purejet TIME 8 ...

Page 215: ...Oil pump OIL PUMP Code Action Duration 1 001019 Mixer belt Replacement 2 001028 Mix gear movement Re placement 3 001018 Mixer Replacement Runner RST Purejet Time TIME 9 ...

Page 216: ...y 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 Driving belt Replacement Time Runner RST Purejet TIME 10 ...

Page 217: ...SMISSION COVER FEMALE SCREW Code Action Duration 1 001096 Transmission crankcase cov er Replacement 2 001135 Transmission cover bearing Replacement 3 001131 Transmission air intake Re placement Runner RST Purejet Time TIME 11 ...

Page 218: ...Water pump WATER PUMP Code Action Duration 1 001113 Water pump Replacement 2 001062 Pump command shaft Re moval and refit Time Runner RST Purejet TIME 12 ...

Page 219: ...Starter motor STARTER Code Action Duration 1 001017 Starter pinion Replacement 2 001020 Starter motor change 3 005045 Starter cable assembly Re placement Runner RST Purejet Time TIME 13 ...

Page 220: ...Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 1 001087 Flywheel cover Replace ment 2 001058 Flywheel Replacement 3 001067 Stator Removal and refit Time Runner RST Purejet TIME 14 ...

Page 221: ...Belt cooling duct BELT REFRIGERATION TUBE Code Action Duration 1 001132 Transmission air intake pipe Replacement 2 001131 Transmission air intake Re placement Runner RST Purejet Time TIME 15 ...

Page 222: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Time Runner RST Purejet TIME 16 ...

Page 223: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement Runner RST Purejet Time TIME 17 ...

Page 224: ...EANER Code Action Duration 1 001014 Air filter Replacement 2 001015 Air filter box Replacement 3 001027 Bodywork cleaner union Replacement 4 004122 Cleaner Throttle body union Replacement Time Runner RST Purejet TIME 18 ...

Page 225: ...Mudguard REAR AND FRONT MUDGUARD Code Action Duration 1 004009 Rear mudguard Replace ment 2 004002 Front mudguard Replace ment 3 006003 Mudguard Painting Runner RST Purejet Time TIME 19 ...

Page 226: ...Radiator RADIATOR Code Action Duration 1 007002 Water cooler Replacement 2 007003 Coolant delivery and return pipe Replacement 3 001052 Coolant Replacement Time Runner RST Purejet TIME 20 ...

Page 227: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Re moval and refit Runner RST Purejet Time TIME 21 ...

Page 228: ...ings STEERING THRUST WASHER Code Action Duration 1 004119 Bearing upper steering fifth wheel Replacement 2 003002 Steering thrust washer Re placement 3 003073 Steering clearance Adjust ment Time Runner RST Purejet TIME 22 ...

Page 229: ...ration 1 002080 Rear brake oil bleeding sys tem Replacement 2 002067 Rear brake pump Replace ment 3 002020 Rear brake pipes Removal and refitting 4 002037 Brake or clutch lever Re placement 5 002071 Left hand grip Replacement Runner RST Purejet Time TIME 23 ...

Page 230: ... Removal and re fit 4 002060 Throttle grip Replacement 5 002059 Right hand grip Replace ment 6 002024 Front brake pump Removal and Refitting 7 002018 Front brake pump Service 8 005017 Stop switch Replacement Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame swinging arm attachment Replacement Time Runner RST Purejet TIME 24 ...

Page 231: ...Seat SEAT Code Action Duration 1 004003 Saddle Replacement compressore aria AIR COMPRESSOR Code Action Duration 1 001168 Air compressor Replace ment Runner RST Purejet Time TIME 25 ...

Page 232: ...allipers REAR BRAKE CALLIPER Code Action Duration 1 003071 Rear brake pads Wear check 2 002002 Rear brake pads replace 3 002068 Rear brake calliper Check 4 002048 Rear brake calliper Re placement 5 002081 Rear brake disc piping Re placement Time Runner RST Purejet TIME 26 ...

Page 233: ...Front brake calliper Remov al 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 RST Purejet Time TIME 27 ...

Page 234: ...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 Replace ment Time Runner RST Purejet TIME 28 ...

Page 235: ...de Action Duration 1 003051 Complete fork Replacement 2 003041 Fork stanchion Replace ment 3 003048 Oil seal fork Replacement 4 003039 Fork leg mandrels Replace ment 5 003010 Front suspension Service Runner RST Purejet Time TIME 29 ...

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