Gilera SMT RCR 633793 Service Station Manual Download

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INDEX OF TOPICS

USPENSIONS

SUSP

Summary of Contents for SMT RCR 633793

Page 1: ...SERVICE STATION MANUAL 633793 633800 SMT RCR ...

Page 2: ... 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 2005 PIAGGIO C S p A Pontedera All rights reserved Reproduction of this pub...

Page 3: ...e to read the sections of this manual concerning special tools along with the special 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...

Page 4: ......

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

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

Page 7: ...s registration number is stamped on the right side of the headstock RCR ZAPG11D1A SMT ZAPG12D1A Dimensions and mass SMT SIZES Specification Desc Quantity Width 805 mm Length 1972 mm Max height 1125 mm Wheelbase 1 355 mm SMT RCR Characteristics CHAR 7 ...

Page 8: ...RCR SIZES Specification Desc Quantity Width 805 mm Length 2036 mm Max height 1222 mm Wheelbase 1 355 mm Characteristics SMT RCR CHAR 8 ...

Page 9: ...ed 23 22 Lubrication Separate oiling mixture oil Fuel supply Petrol oil mixture by carburettor automatic mixer variable flow according to engine speed and throttle valve opening Inlet By means of a compression valve on the casing Cooling system forced coolant circulation system Capacities CAPACITY Specification Desc Quantity Fuel Tank Capacity 7 l Reserve 1 3 l Oil mixer tank Capacity 1 l Reserve ...

Page 10: ...4 Ø 8 8 steel screw on plastic with metallic spacers 2 M4 Ø 8 8 steel screw on brass copper aluminium and their alloys 2 M4 Ø 8 8 steel screw Iron steel 3 M5 Ø 8 8 steel screw on plastic with metallic 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 c...

Page 11: ...d thermistor 32 38 Cylinder head thermostat nut 25 40 Clutch seat 35 45 Crankcase oil drainage cap 10 15 Pinion counterweight 3 5 4 5 Main shaft bearing unit 3 5 4 5 Gearbox sprocket tightening 3 5 4 5 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions brake throttle control and mixer odom eter Oil for 2 stroke engines...

Page 12: ...Specifications PARAFLU MOTO RIDER coolant Ready to use monoethylene glycol anti freeze fluid CUNA NC 956 16 AGIP GEAR 80W 90 gearbox oil SAE 80W 90 oil complying with API GL4 specifications Characteristics SMT RCR CHAR 12 ...

Page 13: ...INDEX OF TOPICS TOOLING TOOL ...

Page 14: ...Crankshaft gear extractor 001330Y Tool for fitting steering seats 002465Y Pliers for circlips 020004Y Punch for removing fifth wheels from headstock 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020329Y MityVac vacuum operated pump Tooling SMT RCR TOOL 14 ...

Page 15: ...Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter 020333Y Single battery charger 020334Y Multiple battery charger 020357Y 32 x 35 mm adaptor 020358Y 37x40 mm adaptor SMT RCR Tooling TOOL 15 ...

Page 16: ...Stores code Description 020363Y 20 mm guide 020376Y Adaptor handle 020412Y 15 mm guide 020425Y Punch for flywheel side oil seal 020439Y 17 mm guide 020441Y 26 x 28 mm adaptor Tooling SMT RCR TOOL 16 ...

Page 17: ...Stores code Description 020455Y 10 mm guide 020456Y Ø 24 mm adaptor 020544y Pliers for clamps 020565Y Flywheel lock calliper spanner 020581Y Flywheel extractor SMT RCR Tooling TOOL 17 ...

Page 18: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 19: ...Brake fluid level check Transmission chain greasing Tension transmission chain check Front fork Check Electrical system and battery check Tyre condition and wear Check Tyres pressure Check Fuel and oil hoses Check Vehicle and brake test road test Engine oil Check Spark plug electrode gap replacement Carburettor Adjustment Clutch control lever Adjustment AT 10 000 20 000 40 000 50 000 KM Action Coo...

Page 20: ... levers greasing Brake pads check Brake fluid level check Transmission chain greasing Tension transmission chain check Front fork Check Electrical system and battery check Tyre condition and wear Check Tyres pressure Check Fuel and oil hoses Check Vehicle and brake test road test Engine oil Check Spark plug electrode gap replacement Carburettor Adjustment Clutch control lever Adjustment Cylinder h...

Page 21: ...arburettor body 8 Pin 9 Minimum nozzle 10 Float 11 Starter nozzle 12 Maximum nozzle 13 Float chamber 14 Diffuser Carburettor Disassemble the carburettor in its parts wash all of them with solvent dry all body grooves with compressed air to ensure adequate cleaning Check carefully that the parts are in good condition SMT RCR Maintenance MAIN 21 ...

Page 22: ... many turns as recommen ded 1 1 4 so as to obtain a first adjustment Warm up the engine and rest the vehicle on a flat surface Tighten the idle speed set screw until the ideal engine idle speed is obtained Engine idle speed 1 900 100 rpm Turn the flow set screw 1 slowly until the max imum rotation rpm possible is obtained Checking the spark advance Engine timing check Remove the crankcase left cov...

Page 23: ...move the spark plug and make sure the electrodes are not worn The central electrode must have clean corners and the external electrode must have a regular thickness Replace the spark plug if signs of wear are detected or the insulator is cracked or chipped Check the electrode gap with a thickness gauges The gap must be 0 6 0 7 mm Electric characteristic Spark plug NGK B8 ES Fit the spark plug manu...

Page 24: ...t with your hands without wringing it let it drip dry and then refit CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER transmissions Transmission adjustment Adjust the control cables Mix cable see Mixer timing section Throttle cable adjust it in such a way that the sheath does not have any clearance Splitter control cable Adjust i...

Page 25: ...perly adjusted when with the scooter upright and without load it looks as indi cated in the figure Chain backlash should be be tween 30 and 45 mm To restore the proper chain tension operate as follows Loosen the wheel pin nut Operate on the set screws until the correct ten sion is obtained Check alignment by means of the notches indi cated on the chain tightener inside the slot on the fork on both...

Page 26: ...H EYES SKIN AND CLOTHING IN CASE OF CONTACT RINSE WITH WATER THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC THAT IS IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE IT WILL LEAD TO INEFFICIENT BRAKING NEVER USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE ALREADY BEEN OPENED OR PARTIALLY USED WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE DO NOT LET ...

Page 27: ...the two screws remove the gasket and top up using only the fluid specified without exceeding the maximum level CAUTION AVOID CONTACT OF BRAKE FLUID WITH EYES SKIN AND CLOTHING IN CASE OF CONTACT RINSE WITH WA TER THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC THAT IS IT ABSORBS HUMIDITY FROM THE SURROUND ING AIR IF THE HUMIDITY IN THE BRAKING FLUID EX CEEDS A CERTAIN VALUE IT WILL LEAD TO INEFFI CIENT B...

Page 28: ...er on a flat ground 10 m away from a half lit white screen Make sure that the scooter axle is perpendicular to the screen Measure the height from the centre of the headlight to the ground and then mark a cross on the wall at the same height measured Start the engine and lock the throttle at 1 3 of its stroke Turn on the low beam light the maximum demarcation limit between the dark and the light ar...

Page 29: ...age plug from the right crankcase cover 1 Remove the oil drainage plug from the central section of the crankcase 2 Clean the drainage plug and its seat and refit the plug WARNING Make sure that the drainage plug gasket is in good conditions Locking torques N m Oil cap 10 Nm Pour oil in the main transmission gearbox through the filler cap 3 Characteristic Capacity 0 65 l SMT RCR Maintenance MAIN 29...

Page 30: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 31: ... engine run for approx five seconds and stopping for other five seconds If the engine fails to start remove the spark plug and make the engine run with open throttle so as to expel fuel in excess Refit a dry spark plug and re peat the procedure If the fuel tank is empty refuel and start up Spark plug faulty or dirty Remove the spark plug and make sure it is clean and in good conditions Adjust the ...

Page 32: ...tarter that stays open Check the mechanical movement Reed valve does not close Check replace the reed pack High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Air filter blocked or dirty Clean according to the procedure Carburettor nozzles loose and or float pin faulty Make sure the nozzles are correctly tightened and that the float pin is correctly tightened and in good condition...

Page 33: ...id 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 within three months If the battery is fitted on a motorcycle be careful no...

Page 34: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 35: ...10 Electric fan pre installation 11 Rear brake STOP button 12 Front brake STOP button 13 Turn indicator switch 14 Left turn rear indicator bulb 15 Tail lights stop light bulbs 16 Right turn rear indicator bulb 17 Left turn front indicator bulb 18 High beam low beam bulb 19 Right turn front indicator bulb SMT RCR Electrical system ELE SYS 35 ...

Page 36: ...el level warning light control 26 Automatic starter pre installation Ar Orange Az Sky Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Electrical system installation Antitheft Remove the headlamp front cowl Operating on the 2 screws shown in the photo graph remove the instrument panel To remove the switch lock unit remove the two screws fixing the unit to...

Page 37: ...nect the electrical connections and re move the switch lock unit Conceptual diagrams Ignition KEY 1 Electronic ignition device 2 Spark plug 4 Magneto flywheel 5 Key switch SMT RCR Electrical system ELE SYS 37 ...

Page 38: ...ts stop light bulbs 18 High beam low beam bulb 20 Light switch 21 Instrument panel A Oil warning light B Temperature warning light C High beam warning light D Turn indicator warning light E Low fuel warning light F Instrument panel bulb 26 Automatic starter pre installation Electrical system SMT RCR ELE SYS 38 ...

Page 39: ...Battery recharge and starting KEY 3 Voltage regulator 4 Magneto flywheel 6 Main fuse 7 Battery SMT RCR Electrical system ELE SYS 39 ...

Page 40: ...panel A Oil warning light B Temperature warning light C High beam warning light D Turn indicator warning light E Low fuel warning light F Instrument panel bulb 22 Timer 23 Engine temperature warning light control 24 Low oil warning light control 25 Fuel level warning light control Electrical system SMT RCR ELE SYS 40 ...

Page 41: ...3 Turn indicator switch 14 Left turn rear indicator bulb 16 Right turn rear indicator bulb 17 Left turn front indicator bulb 19 Right turn front indicator bulb 21 Instrument panel A Oil warning light B Temperature warning light C High beam warning light D Turn indicator warning light SMT RCR Electrical system ELE SYS 41 ...

Page 42: ...he stator components as follows After a sight control of the electrical connections use a specific tester to measure the stator winding and the pick up If checks on the loading coil pick up detect irreg ularities replace the stator and the failing com ponents Disconnect the connector on the flywheel cover and measure the resistance between either con tact and the earthing Specific tooling 020331Y ...

Page 43: ...eristic Resistance 4 6 kOhm Stator check WARNING IF VALUES NON CONFORMING TO THE TABLE ARE DE TECTED CHECK ALL THE ELECTRICAL CONNECTIONS BEFORE REPLACING THE MAGNETO FLYWHEEL RESISTANCE VALUES Specification Desc Quantity 1 White Red 100 Ohm 2 White Green 700 Ohm 3 White Yellow 0 5 Ohm 4 Earth Red 100 Ohm 5 Earth Green 820 Ohm 6 Earth Yellow 0 7 Ohm RESISTANCE VALUES Remove the front left fairing ...

Page 44: ... substitute the fuse with any alternative form of conductor Sealed battery Sealed battery start up operations INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1 Voltage check Before installing the battery on the vehicle check the open circuit voltage with a normal tester If the voltage exceeds 12 60 V the battery may be installed without any renewal recharge If voltage is below 12 6...

Page 45: ... CHILDREN Use of dry cell batteries 1 Having removed the short closed tube and removed the caps put into the elements sulphuric acid of the type for specific weight 1 26 accumulators corresponding to 30 Bé at a temperature of no less than 15 until you reach the upper level 2 Leave to stand for at least 2 hours afterwards top up to the level with sulphuric acid 3 Within twenty four hours recharge w...

Page 46: ...r is not used for a given time 1 month or more it will be necessary to periodically recharge the battery The battery runs down completely in the course of three months If it is necessary to refit the battery in the vehicle be careful not to reverse the connections remembering that the ground wire black marked must be connected to the negative clamp while the other two red wires marked must be con ...

Page 47: ...two fixing wing nuts of the saddle and extract them the battery compart ment is under the saddle The battery is the elec trical device that requires the most frequent inspections and diligent maintenance The main points of maintenance to be observed are as fol lows Check the electrolyte level this must be checked frequently and it must reach the maxi mum level To maintain such level use distilled ...

Page 48: ...tteries contain sulphuric acid Avoid contact with skin eyes and clothing WHEN RECHARGING THE BATTERY MAXIMUM INTENSI TY MUST NOT EXCEED 0 5 1 A OTHERWISE THE BAT TERY WOULD BE SERIOUSLY DAMAGED BATTERIES CONTAIN VERY ENVIRONMENTAL DANGER OUS SUBSTANCES FOR BATTERY REPLACEMENT CONTACT AN AUTHORISED PIAGGIO GILERA SERVICE CENTRE AS THEY ARE EQUIPPED FOR THE DISPOSAL IN AN ENVIRONMENTALLY FRIENDLY AN...

Page 49: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 50: ...silencer to the muf fler Remove the retainer fixing the silencer to the chassis Slide off the muffler Removal of the engine from the vehicle Remove all the plastic parts around the fuel tank Pay attention to the couplings between the plastic parts the fuel tank and the radiator protection grille Engine from vehicle SMT RCR ENG VE 50 ...

Page 51: ... to collect the coolant Remove the following electric wires the cable harness connecting the fly wheel to the coil the cable harness of the coolant sensor the HV cable Remove the carburettor Remove the low pressure pipe control ling the fuel pump Remove the fuel hose Remove the mixer oil hose SMT RCR Engine from vehicle ENG VE 51 ...

Page 52: ...move the oil pump cover and disconnect the metal cable and the hose connecting the oil res ervoir to the mixer Remove the protective platen from the gearbox and the kick start pedal Drain the oil out of the gearbox The oil drainage plug is located in the lower section of the crank case Engine from vehicle SMT RCR ENG VE 52 ...

Page 53: ...erating on the false mesh shown in the photograph Note the correct position of the drive chain upon refitting Remove the clamps fixing the engine to the chas sis indicated in the photograph SMT RCR Engine from vehicle ENG VE 53 ...

Page 54: ... Remove the engine from the chassis by pulling and rotating it slightly Engine from vehicle SMT RCR ENG VE 54 ...

Page 55: ...INDEX OF TOPICS ENGINE ENG ...

Page 56: ...wheel with the aid of the specific calliper spanner and remove the flywheel fixing nut Specific tooling 020565Y Flywheel lock calliper spanner Remove the rotor unit from the flywheel with the aid of the specific flywheel extractor Specific tooling 020581Y Flywheel extractor Detach the fittings of the flywheel cable and the brackets fixing the cables to the chassis Engine SMT RCR ENG 56 ...

Page 57: ...brackets Make sure the cable support inside the crankcase is correctly positioned so that the cables do not get into contact with the flywheel rotor Fit the flywheel rotor making sure that the wrench is aligned with its guide Lock the flywheel using the specific calliper span ner and tighten the flywheel fixing nut Fit the other parts following the removal steps but in reverse order Specific tooli...

Page 58: ...oupling to the cylinder head Connect the coupling from the radiator to the hydraulic pump Fill the cooling system reservoir with coolant Purge the system by operating on the coolant pump cap Locking torques N m Stud bolts 19 Nm Screws 6 Nm Thermoswitch 10 Nm Remove the coolant hose connecting the cylinder to the water pump Use a container to collect the coolant Remove the hose from the head to the...

Page 59: ... housing hole on the crankcase so that no object can fall in Remove the seeger ring retaining the pin The pin The Piston The piston sealing circlips piston rings When pulling the pin be careful to fasten the connecting rod properly to avoid distortions Check and clean the components Clean the piston crown by carefully removing any possible carbon deposits Visually check the piston sealing circlips...

Page 60: ...the gaps of the piston sealing circlips by placing a thickness gauge in the cylinder Characteristic Maximum piston ring gap allowed 0 5 mm Check cylinder for wear with a bore meter Calibrate the bore meter according to the meas urements indicated in the table for the piston cylinder group Measure following the perpendicular axis and at the three different cylinder heights Characteristic Serviceabi...

Page 61: ...ng careful to fit them in their corresponding positions Lubricate both the cylinder and the piston faying surfaces and the sealing circlips Carefully fit the piston in the cylinder being careful to press the sealing circlips in their seats Fit a new head gasket and refit the head on the cylinder Fit a new spark plug Reconnect the temperature sensor connectors and the spark plug cap Fill the coolin...

Page 62: ...the intermediate gear located at the end of the gearbox Remove the gearbox star Warm up the seats of the crankshaft the main shaft and the secondary shaft on both sides at about 60 Place the crankcase on a wooden support as shown in the photograph Separate the two crankcase halves with the spe cific tool Never use a lever or a screwdriver to separate the crankcase halves Replace the crankcase halv...

Page 63: ...1 Engine opening tool Take out the selector guiding fork and the selec tor Take out the two gear shafts at the same time Thoroughly clean and degrease the crankshaft and then inspect it Use a thickness gauge to check the clearance between the connecting rod head and the half shaft Characteristic Serviceability limit 0 8 mm SMT RCR Engine ENG 63 ...

Page 64: ... 35 mm Make sure that both half shafts are not scratched or abnormally worn Use two dial gauges and a support as indicated in the photograph to check the deviation of both half shafts Characteristic Serviceability limit 0 05 mm Selector unit removal Remove the clutch unit Remove the gear pedal 1 Remove the shaft selector unit 2 by pulling it outwards Engine SMT RCR ENG 64 ...

Page 65: ...ite 270 on the thread of the screw of the drum control head Crankcase fitting Fit the new gaskets on the hydraulic pump shaft with the aid of the specific tools Fit the first gasket with its rim facing inside and the second gasket with the rim facing outside Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor 020455Y 10 mm guide Fit the hydraulic pump shaft It is crucial to make sur...

Page 66: ... until it is aligned with the tappet Using a screwdriver rotate the oil pump shaft and the crankshaft so as to engage the oil pump pinions and those of the hydraulic pump Tighten the screws on the crankcase cover in two or three stages tighten one screw first and then the one that is diametrically opposite Locking torques N m Crankcase right cover 8 10 Nm Fit the oil pump and the hose support Fit ...

Page 67: ...ate the clutch shaft anti clockwise and then fit the clutch lever with its screws Adjust the clutch lever clearance to a value be tween 2 and 4 mm handlebar left side Fit the connecting coupling between the hydraulic pump and the radiator and between the hydraulic pump and the cylinder Fit the rear brake pump and the brake fluid res ervoir Pour recommended oil in the crankcase Fill the cooling sys...

Page 68: ...nkcase at about 90 To fit the new bearing warm up the seat at about 90 Using a punch push the bearing until it stops Thoroughly clean and degrease the gear shaft and then inspect it Carry out a visual inspection of the gears Re place the gears if they show signs of overheating or surface softening or abnormal wear of gears teeth Replace the whole shaft if it is damaged or ab normally worn Engine S...

Page 69: ...een re moved Check the gear studs and clefts are not rounded or show signs of abnormal use Check the secondary shaft rings for wear Replace them if 25 of their surface is worn Make sure that the secondary shaft roller bearing show no signs of wear Replace it if worn SMT RCR Engine ENG 69 ...

Page 70: ...he selector Lubricate the surfaces with spe cific oil Make sure that the gearbox works properly by selecting different speed ratios and turning the gear selector drum to both sides Select neutral gear and check that the system rotates freely Refit the crankcase by warming up the shaft seats at about 60 Tighten the screws to the prescribed torque Make sure the crankshaft and the gear rotate freely ...

Page 71: ...nd lift the clutch internal cover Remove the 3 clutch plates and the two steel discs Straighten the bevelled washer Lock the hub with the specific tool and unscrew the nut with a M17 wrench Detach the locking washer and the star washer Remove the clutch hub SMT RCR Engine ENG 71 ...

Page 72: ...g when exten ded Characteristic Spring serviceability limit 31 mm Check the clutch plate Measure the thickness of each plate Characteristic Serviceability limit 3 8 mm Check the steel disc Use thickness gauges to check that the plates are not distorted Characteristic Serviceability limit 0 15 mm Engine SMT RCR ENG 72 ...

Page 73: ...etween the surface and the plate is not eroded or grooved Replace the part if any defect is found CAUTION REPLACE THE PART IN CASE OF EXCESSIVE DAMAGE Check the pressure disc and its axial bearing CAUTION REPLACE THE PART IN CASE OF EXCESSIVE DAMAGE Pinion fitting Insert the wrench in the crankshaft and then fit the main transmission gear Fit the hydraulic pump and the oil pump driving gear Lock t...

Page 74: ...tch Drain the oil out of the gearbox and the clutch Remove the oil pump cap Partially lift the lockscrew fixing the oil cable with the aid of a small screwdriver Rotate the pump valve control anticlockwise and detach the oil pump cable Remove the hose support Undo the two screws fixing the oil pump Move the whole oil pump unit and its hoses to wards one side of the carburettor but do not detach th...

Page 75: ...of old gaskets that may be left on the coupling surfaces of the hydraulic pump Lock the driving gear 1 Unscrew the fixing nut 2 first and then the rotor 3 Push the driving gear remove the hydraulic pump and the gaskets Remove the seeger ring 4 Remove the oil pump 5 Main transmission pinion Remove the crankcase right cover and the clutch hub SMT RCR Engine ENG 75 ...

Page 76: ...agneto flywheel and then loosen the main transmission gear fixing nut and the pump driving gear Remove the hydraulic pump and the oil pump driving gear Remove the main transmission gear using the specific tool Specific tooling 0 0H 056 0 032 1 Crankshaft gear extractor Clutch fitting Fit the clutch bushing washer and its shell Engine SMT RCR ENG 76 ...

Page 77: ...locking washer and the fixing nut Lock the hub using the specific tool and tighten the locking nut using the appropriate M17 wrench Fold the locking washer to secure the nut Lubricate the clutch plates with new oil Fit the transmission discs with the visible circle on one of the clutch surfaces facing out Fit the clutch internal cover with the Gilera logo in line with the visible notch on one of t...

Page 78: ...ove the pump opening control cable by op erating first on the set screw retainer indicated in the photograph and then on the pump cam retainer Remove the two screws fixing the pump to the crankcase Remove the pump Make sure the pump drive rotates freely Make sure the sealing rings are in good condi tions Replace them if they are damaged or dis torted The oil pump is a safety element for proper en ...

Page 79: ...y hoses to facilitate drainage until the oil flow is constant and no air bubbles are formed Tighten the bleed screw 1 Pipe purging Fill up the fuel tank with a mixture of oil and petrol at 2 5 using the oil recommended for this type of engine Start the engine and let it run for about 10 minutes with the oil pump control lever 2 fully open in or der to send out all the air in the pipe together with...

Page 80: ...e plate limiting reed opening by undo ing the three screws fixing the reed support Fit the valve following the removal procedure but in reverse order make sure the plate limiting reed opening has been correctly positioned Absence of the plate limiting reed opening com promises the engine performance and reliability Check the O ring of the reed support Replace it if damaged or distorted TYPE PHVA 1...

Page 81: ... fuel valve low pres sure pipe Operating on the screw indicated in the photo graph remove the throttle valve and its tapered pin Compress the throttle valve return spring Remove the safety cap in the throttle valve and remove the throttle control cable from the valve Remove the starter fixing cotter by undoing the screws indicated in the photograph Remove the starter control SMT RCR Engine ENG 81 ...

Page 82: ...thin pin Remove the maximum nozzle the minimum noz zle and the starter nozzle Refitting the carburettor Thoroughly clean all the carburettor components with solvent Be careful not to damage the carburettor gasket and the starter control O ring Blow short blasts of compressed air through all the carburettor nozzles including the oil and petrol intake nozzles Engine SMT RCR ENG 82 ...

Page 83: ...ood conditions Replace it if damaged or distorted Make sure the starter control piston is in good conditions Replace it if it shows signs of abnormal wear Check that the calibration of the nozzles is ade quate refer to the carburettor calibration table Failure to observe these values compromises engine performance SMT RCR Engine ENG 83 ...

Page 84: ...richer mixture Thus carburetion can be adapted to different weather conditions Replace the tapered pin if it shows signs of wear as shown in the photograph Check that idle set screw shows no signs of ab normal wear This is detrimental to correctly adjust idle speed Make sure the throttle valve does not show scratches comprising 25 of its overall surface Replace if it does Engine SMT RCR ENG 84 ...

Page 85: ... pressure pipe for the fuel cock control Adjusting the idle Tighten the flow set screw slowly until it stops and then unscrew it as many turns as specified for this type of engine 1 1 4 Remember this is the first adjustment Warm the engine up to the regular operating tem perature Adjust the idle speed at 1600 200 rpm by op erating on the idle speed set screw 2 Turn the flow set screw 1 to both dir...

Page 86: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 87: ...he stem adequately in the vice with alu minium clamps to avoid scratching the stem Loosen the upper screw Remove the stem upper lock together with the preloading bushing Remove the spring Prepare a container to collect the oil present in each stem Measure the amount SMT RCR Suspensions SUSP 87 ...

Page 88: ... a screw driver Remove the lower screw located on the fork leg in order to release the stem from the fork leg Remove the stem from the fork leg Remove the aluminium bushing that guides the stem into the fork leg Suspensions SMT RCR SUSP 88 ...

Page 89: ...emove the oil seal as indicated in the photograph Always replace the oil seal upon refitting Clean and degrease all the components of the front suspension Check all the parts related to the suspension Check the guide bushings for wear Replace them if there are signs of wear on the surface Check the guide bushings on the fork leg for wear Replace them if they show signs of abnormal wear SMT RCR Sus...

Page 90: ...gns of abnormal wear or distortions Replace it if it does Check if the return spring and the guide nylon ring are in good conditions Replace them if damaged or distorted Thoroughly clean all the components Refitting Carry out removal operations in reverse order being careful to observe the following tightening torques REFITTING Name Torque in Nm Fork stem cap 17 19 Nm Fork plate upper clamp 8 10 N...

Page 91: ...intenance Replace it if there are any signs of malfunctioning In RCR version rear suspension maintenance operations must be carried out frequently espe cially every time the scooter is used in dusty or muddy areas Afterwards clean and lubricate the connecting arms in the areas where they are linked to the chassis and the shock absorber SMT RCR Suspensions SUSP 91 ...

Page 92: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 93: ... brake pipe from the calliper pour the fluid inside a container Remove the mountings indicated in the figure When refitting tighten the nuts to the prescribed torque Purge the system Locking torques N m Fixing screws 17 19 Nm Rear brake disc Rear brake disc replacement Support the scooter rear carriage axle adequate ly so that the rear wheel does not touch the ground Remove the rear wheel operatin...

Page 94: ... the disc correctly making sure that it rotates in the right direction Locking torques N m Front brake disc 10 12 Nm Disc Inspection Remove the wheel and check for unevenness of the disc Maximum permissible out of true is 0 1 mm If the value measured is greater replace the disc and repeat the check If the problem persists check and replace the wheel rim if necessary Braking system SMT RCR BRAK SYS...

Page 95: ...wo brake calliper clamps shown in the figure With the calliper removed from the support but still connected to the oil pipe remove the two pad locks Pads must be replaced if the friction material thickness is less than 1 5 mm SMT RCR Braking system BRAK SYS 95 ...

Page 96: ...eplacement Support the scooter rear carriage axle adequate ly so that the rear wheel does not touch the ground Remove the rear wheel axle operating on the nut indicated in the photograph With the calliper removed but still connected to the oil pipe remove the two pad locks Remove the 2 pads and the two metal plates Braking system SMT RCR BRAK SYS 96 ...

Page 97: ...ed screws When purging it is necessary to refill the oil reservoir permanently while working with a Mi tyvac pump on the bleed screw until no more air comes out of the system The operation is finished when just oil comes out of the bleed screws Do up the bleed screw N B IF AIR CONTINUES TO COME OUT DURING PURGING EXAMINE ALL THE FITTINGS IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY LOOK FOR ...

Page 98: ...CAREFULLY DRY THE CALLIPER AND DE GREASE THE DISC SHOULD THERE BE OIL ON IT WHEN THE OPERATION IS OVER TIGHTEN THE OIL BLEED SCREW TO THE PRESCRIBED TORQUE CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES SKIN AND CLOTHING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS CAUTION THE BRAKE FLUID IS ...

Page 99: ...N THE BRAKING FLUID EXCEEDS A GIVEN VALUE BRAKING EFFICIENCY WILL BE REDUCED THEREFORE ALWAYS USE FLUID FROM SEALED CONTAINERS UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY 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...

Page 100: ...ndoing the two clamps shown in the figure Upon refitting carry out the removal operations but in reverse order observing the tightening tor ques CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES SKIN AND CLOTHING IN CASE OF ACCIDENTAL CONTACT WASH WITH WATER WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS CAUTION THE BRAKE FLUID IS HYGROSCOPIC...

Page 101: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 102: ...the system System bleed Drain the coolant circuit by removing the screw shown in the figure and the expansion tank filler plug Detach the sleeve connecting the hydraulic pump to the radiator Collect the coolant in a clean container WARNING CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD SCALDING COOLANT OR ITS VAPOURS CAN CAUSE SERIOUS BURNS COLLECT THE COOLANT IN A CONTAINER COOLANT IS HARMFUL...

Page 103: ...crankcase right cover Remove the hydraulic pump shaft 1 and the transmission pinion 2 As soon as there is the slightest indication of coolant or oil leaking from the breather replace the gaskets of the hydraulic pump shaft Fit the new gaskets as shown in the next layout Hydraulic pump fitting SMT RCR Cooling system COOL SYS 103 ...

Page 104: ...se order Thermostat Removal Drain out the cooling system Detach the sleeve from the cylinder head Undo the thermostat screw 1 and the thermo stat itself Take out the thermoswitch fitting 2 Detach the thermoswitch 3 Check Thermoswitch check Immerse the thermoswitch in hot water to check its resistance The thermoswitch should not get into contact with the container walls or bottom otherwise the read...

Page 105: ...1 Thermometer 2 Thermostat the thermostat must be totally im mersed into the water Replace the thermostat if the results do not fall within the specification values Characteristic Valve opening at 67 3 C 0 1 mm Valve opening at 75 C 3 mm Refitting Fit the thermoswitch 3 Connect the connector 2 to the thermoswitch Fit the thermostat and its fixing screw 1 Connect the sleeve to the cylinder head Fil...

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

Page 107: ...icated in the photograph Headlight assy Headlamp front cowl replacement Remove the rubber connections from the slots as indicated in the figure Remove the headlamp retaining bracket from the front cowl by gently pressing the bracket as indi cated in the figure SMT RCR Chassis CHAS 107 ...

Page 108: ... the turn indicators sup port bracket from the front cowl Front headlight replacement After removing the headlamp front cowl and in order to remove the headlight operate on the tabs indicated in the photograph and on the headlamp fixing adjustment screws Chassis SMT RCR CHAS 108 ...

Page 109: ...rests Side fairings Rear fairings Remove the saddle Remove the two fixing screws indicated in the photograph Remove the screw shown in the figure and loca ted under the side fairing Air deflector Undo the two screws indicated in the photograph to remove the air deflector SMT RCR Chassis CHAS 109 ...

Page 110: ...iring replacement To replace the fairing halves remove the fixing screws indicated in the figure Rear mudguard Remove the rear mudguard by loosening the 4 screws indicated in the figure Chassis SMT RCR CHAS 110 ...

Page 111: ...at Front mudguard Remove the 4 screws shown in the figure the transmission clamps and the mudguard Radiator fan Radiator removal Remove the front fairing Remove the radiator clamp indicated in the pho tograph Using the specific pliers disconnect the coolant pipes WARNING CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD SCALDING COOLANT OR ITS VAPOURS CAN CAUSE SERIOUS BURNS COLLECT THE COOLANT I...

Page 112: ...wo screws shown in the figure and the pipes connected to the reservoir Remove the reservoir Mixture oil tank Remove the saddle Remove the rear fairings Remove the oil intake pipes and drain out the mixer oil reservoir Remove the electric connections from the oil level indicator Slide off the reservoir from its seat Battery Battery compartment Remove the rear mudguard Remove the side fairings Remov...

Page 113: ...SMT RCR Chassis CHAS 113 ...

Page 114: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 115: ...FORMANCE 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 FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE CAUTION WHEN INSTALLING TH...

Page 116: ... A FIRE Levels check Level check Brake oil level Gearbox oil level Mixer oil level Road test Test drive Cold start Speedometer operation check Throttle control operation Riding stability Rear and front brake efficiency Front and rear wheel shock absorber Abnormal noise Restarting when warmed up Fluid leakage after the road test Static test Static check Tyre pressure Correct operation of all locks ...

Page 117: ...Be very careful when handling fuel Functional inspection Functional check Brake lever travel Throttle control adjustment and free travel Uniform turning of the steering SMT RCR Pre delivery PRE DE 117 ...

Page 118: ... B Battery 33 39 44 45 47 112 Brake 93 96 100 C Carburettor 21 80 82 Coolant 102 F Fuel 32 79 111 Fuses 44 H Headlight 28 107 I Identification 7 M Maintenance 19 S Spark plug 23 T Tank 111 112 Transmission 32 Tyres 10 ...

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