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PIAGGIO NRG POWER PUREJET Workshop Manual Download Page 130

EMS 

SYSTEM

Specification

Desc./Quantity

1

Digital instrument unit

2

Fuse 5A

3

Key switch contacts

4

EMS diagnostic socket

5

Fuel pump

6

Battery

12V - 9Ah

7

Fuse

20A

8

Air injector

9

Throttle position sensor

10

HV coil

11

Flywheel magneto

12

Voltage regulator

13

Fuel injector

14

Water temperature sensor

15

Injection ECU

pure jet injection

NRG Power Purejet

INJ PJ - 14

Summary of Contents for NRG POWER PUREJET

Page 1: ...WORKSHOP MANUAL 633265 NRG Power Purejet...

Page 2: ...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 publicati...

Page 3: ...e sections of this manual relating to specific tools along with the specific tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to spec...

Page 4: ......

Page 5: ...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...

Page 6: ......

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

Page 8: ...do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lu...

Page 9: ...ZAPC45200 1001 Engine prefix C452M Dimensions and mass DIMENSIONS AND MASS Specification Desc Quantity Max length 1790 mm Max width 850 mm Seat height 795 mm Wheelbase 1280 mm Dry weight 99 kg NRG Po...

Page 10: ...pregnated with fuel mixture 50 SE LENIA air filter oil and 50 unleaded petrol Starting system electric starter kickstarter Cooling system forced coolant circulation system Lubrication Engine lubricati...

Page 11: ...o the ignition system Recommended spark plug type CHAMPION RG6YCA Battery 12V 9Ah Main fuse 20A Generator Three phase alternating current Frame and suspensions FRAME AND SUSPENSIONS Specification Desc...

Page 12: ...Nm Bolt holding stand to the engine 18 to 19 Nm Side stand fixing screw 12 20 Side stand bracket fixing screw 15 20 Rear rim fixing screw 20 25 FRONT SUSPENSION Name Torque in Nm Front wheel axle nut...

Page 13: ...2 13 Ignition spark plug 25 30 Hub oil drainage cap 3 5 Oil hub level dipstick Manual Rear hub cap screws 12 13 Transmission cover screws 12 13 Inlet manifold screws 8 9 Flywheel hood fixing screws 1...

Page 14: ...fitting P2 40 418 40 425 40 364 40 371 0 047 0 061 Piston rings SEALING RINGS Name Description Dimensions Initials Quantity Compression ring 40 A 0 10 to 0 25 Compression ring 1st oversize 40 2 A 0 10...

Page 15: ...e cylinder without installing the basic gasket Apply a centimetre dial gauge on the special tool and zero it on the ground plane Fit the tool to the top of the cylinder fixing it with two nuts to the...

Page 16: ...SO L EGD AGIP GP 330 Grease for brake levers throttle White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 AGIP GREASE SM 2 Grease for the tone wheel revolv ing ring Soap based lithi...

Page 17: ...INDEX OF TOPICS TOOLING TOOL...

Page 18: ...6 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Pliers to extract 17 mm bear ings 001467Y009 Driver for OD 42 mm bearings 001467Y013 Pliers to extract 15 mm bear i...

Page 19: ...01467Y017 Bell for bearings outside 39 mm 001467Y021 Extraction pliers for 11 mm bearings 001467Y029 Bell for bearings O D 38 mm 002465Y Pliers for circlips 004499Y Camshaft bearing extractor NRG Powe...

Page 20: ...el 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 remo...

Page 21: ...151Y 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 NRG Po...

Page 22: ...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 Too...

Page 23: ...tion 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 NRG Power Pure...

Page 24: ...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 adap...

Page 25: ...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 NRG Power Purejet...

Page 26: ...020456Y 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 NR...

Page 27: ...iper 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 pre...

Page 28: ...Stores code Description 020620Y Water pump impeller stop 020621Y HV cable extraction adaptor Tooling NRG Power Purejet TOOL 12...

Page 29: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 30: ...replacement Air filter clean Oil mixer throttle linkage adjustment Coolant level check Brake control levers greasing Brake pads check condition and wear Brake fluid level check Electrical system and b...

Page 31: ...pressure and wear check SAS box sponge cleaning Vehicle and brake test road test See the regulations of the Secondary air system section AT 20000 KMS AND 40000 KMS 120 Action Hub oil change Spark plug...

Page 32: ...battery check Headlight adjustment Tyre pressure and wear check SAS box sponge cleaning Vehicle and brake test road test See CO regulation in the Adjusting the engine idle section See rules in the Se...

Page 33: ...he gap between the electrodes with a feeler Adjust the gap if necessary carefully bending the side electrode In the event of defects replace the spark plug with the prescribed type Position the spark...

Page 34: ...level is slightly over the second notch starting from the lower end 4 Screw the dipstick back in checking that it is locked in place Recommended products AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil...

Page 35: ...air filter sponge Mineral oil with specific additives for increased ad hesiveness Checking the ignition timing Adjust the control cables Mix cable see procedure indicated in Mixer tim ing Throttle cab...

Page 36: ...SCREWS SEE THE ARROW IN THE FIGURE UNTIL THE OIL BEGINS TO FLOW OUT TIGHTEN THE SCREWS START UP THE ENGINE AND WAIT FOR OIL TO FLOW OUT OF THE TUBE RECONNECT THE DELIV ERY PIPE TO THE CARBURETTOR AND...

Page 37: ...ENT OF MOISTURE IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE BRAKING WILL BE INEF FICIENT NEVER USE BRAKE LIQUID IN OPEN OR PAR TIALLY USED CONTAINERS UNDER NORMAL CLIMATIC CONDITIONS THE FLUID MUST B...

Page 38: ...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 REGARDIN...

Page 39: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 40: ...iven pulley using only Montblanc Mo libdenum Grease dis 498345 grease Transmission belt worn Replace Roller wear Presence of oil Dirt Clean the speed variator replace the rollers if worn out Rear whee...

Page 41: ...and check the plug gap Transmission and brakes Clutch grabbing or performing inadequately CLUTCH Possible Cause Operation Tear or irregular functioning Check that the masses open and return normally C...

Page 42: ...ssible Cause Operation Defective piston sliding Check calliper and replace any damaged part Deformed brake disc Use a comparator to check the disc planarity with the wheel correctly mounted Electrical...

Page 43: ...ng the steering even after making the above adjustments check the seats in which the ball bearings rotate replace if they are recessed Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cau...

Page 44: ...ation if there is noise or seiz ing overhaul the final reduction assembly Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Shock absorbers malfunctioning Replace the complet...

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

Page 46: ...or 5 High low beam selector 6 Rear brake stop button 7 Complete headlight 8 2 lamps for parking light 12V 3W 9 Lamp for dipped beam light 12V 35W 10 Lamp for high beam light 12V 35W 11 Instrument unit...

Page 47: ...or 24 Front right indicator with lamp 25 Complete resistance 26 Battery 12V 9A 27 Fuse 20A 28 Fuse 5A 29 Petrol injector 30 Air injector 31 Water temperature sensor 32 Throttle body sensor 33 Output f...

Page 48: ...ON Specification Desc Quantity 1 Battery 12V 9Ah 2 Fuse 20A 3 Key switch contacts 4 Voltage regulator 5 Ignition spark plug 6 HV coil 7 Flywheel magneto 8 Pick up 9 CPU Electrical system NRG Power Pur...

Page 49: ...NDICATORS Specification Desc Quantity 1 Flywheel magneto 2 High beam bulb Type H8 Power 12V 35W Quantity 1 3 Digital instrument unit 4 Voltage regulator 5 Low beam bulb Type H8 Power 12V 35W Quantity...

Page 50: ...Battery 12V 9Ah 9 Front parking light Type All glass Power 12V 3W Quantity 2 10 Turn indicator control device 11 Fuse 5A 12 Turn signal switch 13 4 turn indicator lamps 12V 10w Battery recharge and st...

Page 51: ...gulator 5 Starter motor 6 Fuse 20A 7 Key switch contacts 8 Battery 12V 9Ah 9 Starter remote control 10 Starter button 11 Fuse 5A 12 Fuse 5A 13 Diode 14 Two brake light buttons 15 Mixture oil level sen...

Page 52: ...ent power supply 3 Earth 4 Grounding for phonic wheel 5 Power supply to phonic wheel 6 Phonic wheel signal 7 Instrument light and parking light indicator 8 Instrument temperature mass 9 Not connected...

Page 53: ...the connector from the voltage regu lator and check for continuity between each yellow wire with the other two Ohm value 0 7 0 9 Ohm Also check that each yellow wire is isolated from the ground If non...

Page 54: ...d voltage 12V Rated power 0 25 kW Left rotation viewed from pinion side Connection to engine with pinion and crown wheel on transmission side crankshaft Control with button Tests to perform to check t...

Page 55: ...n 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 e...

Page 56: ...y 12V 9Ah Ammeter See also Centre stand Side fairings Turn signals system check The turn signal circuit is managed by an intermit tent device If there is a fault in the turn signal circuit check The 5...

Page 57: ...of the fuel level by moving the arm with float Limit values empty tank position 87 103 Ohm tank position 34 42 Ohm full tank position or equal to 7 Ohm See also Air duct The oil mix lamp carries out a...

Page 58: ...e Make sure the lamp holder earth is present See also Air duct Sealed battery Airtight battery start up operations INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1 Voltage check Befor...

Page 59: ...ed 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 B at a temperature of at least 15 C until reaching the upper...

Page 60: ...ttery is being charged the voltage of each element must be 2 6 2 8V The discharge limit of each element is 1 8V When charging is completed check the level and density of the electrolyte as well as the...

Page 61: ...SES 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 DECREAS...

Page 62: ...Electrical system NRG Power Purejet ELE SYS 18...

Page 63: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 64: ...er cables 7 Detach the mixture oil fuel and vacuum pump outlet tubing 8 Detach the H T cable from the spark plug 9 Remove the rear shock absorber fixing bolt from the engine 10 Remove the nut on the l...

Page 65: ...INDEX OF TOPICS ENGINE ENG...

Page 66: ...RANKCASE Air duct Remove the Radiator grill Remove the air conveyor by disengaging the special joints See also Front central cover Removing the driven pulley shaft bearing Slightly heat the crankshaft...

Page 67: ...ulley Lock the clutch bell housing with the specific tool Remove the nut the clutch bell housing and the whole of the driven pulley assembly N B THE UNIT CAN ALSO BE REMOVED WITH THE DRIVE PULLEY MOUN...

Page 68: ...components Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass friction material The masses must not show traces o...

Page 69: ...ON THE HOLDING EDGE OF THE EX TRACTION 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 sna...

Page 70: ...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 diame...

Page 71: ...THE BEARINGS ARE BEING FITTED Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for 17 mm roller case Refitting the driven pulley Check the surfaces cont...

Page 72: ...e clutch Preassemble the driven pulley group with spring sheath and clutch Position the spring with the sheath Insert the components in the tool and preload the spring being careful not to damage the...

Page 73: ...e toothed grooves Check 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 n...

Page 74: ...ace and that the metallic insert does not come out of the plastic shell borders 4 Check the integrity of the sliding blocks of the contact plate Check that the internal bushing shown in the fig ure is...

Page 75: ...ng washer stationery half pulley cooling fan belt with drive washer and nut Tighten the lock nut to torque 20 Nm and then perform a final 90 lock preventing the rotation of the drive pulley with the s...

Page 76: ...emove 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...

Page 77: ...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 re...

Page 78: ...r 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 R...

Page 79: ...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 1...

Page 80: ...olutions 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 4...

Page 81: ...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 respons...

Page 82: ...e 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 c...

Page 83: ...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 fig...

Page 84: ...E 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 fi...

Page 85: ...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...

Page 86: ...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 S...

Page 87: ...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 posi...

Page 88: ...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 po...

Page 89: ...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...

Page 90: ...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 inje...

Page 91: ...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...

Page 92: ...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 care...

Page 93: ...de 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 Bearin...

Page 94: ...l 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...

Page 95: ...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...

Page 96: ...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 fit...

Page 97: ...R 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...

Page 98: ...wheel side us ing the thermal gun with the same procedure on the transmission side crankcase half Keep the transmission side crankcase half in hor izontal position to introduce the flywheel side crank...

Page 99: ...y Insert the other 5 screws and tighten them to the specified torque Locking torques N m crankcase coupling screws 11 13 Move the crankcase separation plate in a position back from the one indicated i...

Page 100: ...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...

Page 101: ...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...

Page 102: ...ling 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 cov...

Page 103: ...h 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 F...

Page 104: ...e driving pulley Remove the 2 screws shown in the figure Remove the pipe gasket from the case as shown in the figure Remove the pipe from the oil inlet union in the pump case See also Removing the dri...

Page 105: ...Refitting To refit perform the removal procedures in the reverse direction Perform purging after refitting using the screw shown in the figure NRG Power Purejet Engine ENG 41...

Page 106: ...Engine NRG Power Purejet ENG 42...

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

Page 108: ...ention in repositioning the odometer drive correctly Locking torques N m Wheel fixing nut 40 to 50 N m Handlebar Removal Remove the front handlebar cover Remove the rear handlebar cover After removing...

Page 109: ...2 ISO L XBCIB2 Locking torques N m Locking torque 65 to 70 N m Front fork Removal Remove the front brake calliper Remove the odometer cable from the reduction gear box Remove the front mudguard Remove...

Page 110: ...dlock nut Specific tooling 020150Y Air heater support 020151Y Air heater Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking torques N m Stud sta...

Page 111: ...K 20 Refitting Lubricate the seats and the balls with the grease recommended Lock at the prescribed torque and turn the key anticlockwise by 90 to 100 Specific tooling 020055Y Wrench for steering tube...

Page 112: ...oling 020004Y Punch for removing fifth wheels from headstock Refitting Lower and upper races from frame refitting Using the special tool refit the upper and lower bearing seats on the headstock Specif...

Page 113: ...from headstock Always use a new fifth wheel seat on refitting Using the special tool refit the fifth wheel seat with the aid of a few mallet blows and bring it as far as the stop shown in the photo S...

Page 114: ...lace the shock absorber you just need to remove the battery access flap to get and remove the shock absorber frame anchorage nut Then remove the shock absorber engine anchorage nut Refitting When refi...

Page 115: ...E NEW O RING AND PIN GREASE THE SPRING ATTACHMENTS AND THE PIN Expelling stand pivot pin from bracket Remove the stand support bracket from the en gine Drill a 5 mm hole in the bracket so that the pin...

Page 116: ...Suspensions NRG Power Purejet SUSP 10...

Page 117: ...INDEX OF TOPICS PURE JET INJECTION INJ PJ...

Page 118: ...as 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...

Page 119: ...ed conditions The solid light denotes serious faults that impair the engine functions precautionary measures 1 Before fixing any part of the injection system check any registered faults Never disconne...

Page 120: ...e 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 cau...

Page 121: ...meter with internal resistance of more than 10 Ohm V Inappropriate 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...

Page 122: ...PC IN THE MENU The main menu of the diagnostic tester has the following functions PARAMETERS ERRORS PARAMETERS STORED ERROR CLEARING ACTIVE DIAGNOSTIC TPS RESET CALIBRATION ECU INFORMATION To access t...

Page 123: ...from the outlet Reapply the protection cap to the outlet to prevent dirt from laying onto the contacts Refit the battery cover PARAMETETERS Specification Desc Quantity ENGINE RPM Displays the regime o...

Page 124: ...s STALL stationary CRANK starting IDLE idle RUN running RUNNING HOURS Displays the engine running time in hours S T FUEL PUMP Denotes the status of the fuel pump OFF ON TPS TO RESET Indicates the need...

Page 125: ...ine phase point Engine with stall Light on G40 P0700 Belt CVT With engine idle or during start up the automatic transmission or the clutch has required an excess driving force The fault is registered...

Page 126: ...denotes STORED the faults displayed in CURRENT or OCCURRED automatically shifts to STORED after switching to OFF The passage to STORED always occurs at the end of the period of use N B THE FAULT CAN B...

Page 127: ...irmed 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 enabled the tester displa...

Page 128: ...signal 7 Signal TPS 1 8 9 Coolant temperature sensor positive 10 SignalTPS 2 11 12 HV coil negative 13 Air injector negative 14 Fuel pump negative 15 ECU power supply 12V 16 Coolant sensor and TPS se...

Page 129: ...21 Serial line for diagnostic tester 22 EMS system diagram NRG Power Purejet pure jet injection INJ PJ 13...

Page 130: ...witch contacts 4 EMS diagnostic socket 5 Fuel pump 6 Battery 12V 9Ah 7 Fuse 20A 8 Air injector 9 Throttle position sensor 10 HV coil 11 Flywheel magneto 12 Voltage regulator 13 Fuel injector 14 Water...

Page 131: ...cpu power circuit ECU POWER SUPPLY CIRCUIT Specification Desc Quantity 1 Digital instrument unit NRG Power Purejet pure jet injection INJ PJ 15...

Page 132: ...form all the checks required in the injection light section 5 Connect the diagnostic tester of scooter Select the errors function and check the faults that are signalled in current status GO TO point...

Page 133: ...020460Y Scooter diagnosis and tester 15 Check the charger GO TO point 17 16 The ECU supplies are conform 17 Check all electrical installation connections for any possible problems that are related to...

Page 134: ...point 25 NO point 26 25 The supply is conform 26 Check the efficiency of the 15A fuse and of the connections to the fuse holder red blue YES point 27 NO point 28 27 Restore the continuity of the line...

Page 135: ...adjuster GO TO point 24 34 After confirmation of the correct main supply point B check the power supply to panel Check the following conditions 1 17 battery voltage switch on ON 1 17 0V switch on OFF...

Page 136: ...nnect the specific tool with the ECU Mount a new 20A fuse Check the following con ditions 1 17 battery voltage switch on ON 1 17 0 Volt switch on OFF YES point 45 NO point 44 44 IlThe fuse is again bu...

Page 137: ...CU not responding check connections proceed as follows Specific tooling 020460Y Scooter diagnosis and tester 1 Check that the insertion of the connection to the vehicle is correct YES point 3 NO point...

Page 138: ...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 wiring continui...

Page 139: ...ERMIC 1 4 CONDITIONS Key selector set to ON engine off STANDARD Less than 0 1 V THERMIC 1 4 CONDITIONS Key selector set to ON engine on no fault detected STANDARD Battery voltage NRG Power Purejet pur...

Page 140: ...INJECTION LAMP CIRCUIT Specification Desc Quantity 1 Digital instrument unit 2 Fuse 5A 3 Key switch contacts 4 Fuel pump 5 Injection ECU pure jet injection NRG Power Purejet INJ PJ 24...

Page 141: ...tant confirming that the ECU is operational The operation of the autodiagnosis lamp is also enabled on the injection lamp circuit Specific tooling 020460Y Scooter diagnosis and tester 1 Connect the sc...

Page 142: ...s Check the presence of volt age between white lead and black lead Black 2 4 White 5 8 battery voltage with switch to ON YES point 10 NO point 9 9 Positive power to panel missing This comes from the s...

Page 143: ...tore the wiring throttle position sensor circuit T P S TERMINALS 16 18 CONDITIONS Key switch set to ON STANDARD VALUES 5V TERMINALS 16 7 CONDITIONS Key switch set to ON opening the gas gradually STAND...

Page 144: ...The TPS1 signal increases with increased throttle opening The TPS2 signal decreases with increased throttle opening The two signals are equivalent at a single point corresponding to average opening 50...

Page 145: ...creases progressively TPS2 Decreases progressively Set the valve opening to 50 and check that at this value the signals TPS1 and TPS2 are equal or very close a few hundreds volts difference N B FOR A...

Page 146: ...7 TPS2 The voltage of TPS2 signal in not as ex pected 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 tem...

Page 147: ...store the wiring GO TO point 4 6 Check the wiring 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...

Page 148: ...th the opening from 4 5 to 0 5V Voltage variations must be progressive with gas opening without stall or direction reversal The sum of voltages TPS1 and TPS2 must be constant and with values slightly...

Page 149: ...ion and excludes the idle and the CUT OFF management This result can be obtained by recovering the pre calibration and keying tolerances of the TPS sensor on the throttle body This occurs by resetting...

Page 150: ...e 4 The diagnostic tester responds NO The reset procedure was successful GO TO point 5 5 For a further confirmation check the following indications of the parameters function TPS1 OUTPUT V 0 64 TPS2 O...

Page 151: ...int 4 3 Errors present Cancel all errors Press a key GO TO point 5 4 No errors Press a key GO TO point 6 5 Check the auto diagnostic content and make the necessary repairs GO TO point 1 6 TPS reset in...

Page 152: ...onfirmation check that the indications reported in the parameters function comply with the instructions given for automatic reset rpm timing sensor circuit TERMINALS 19 20 CONDITIONS Engine driven by...

Page 153: ...r position occurs via alternations separated by 30 of rotation due to the missing teeth The electrical lines connected with the ECU are polarised to guarantee correct timing The positive peak of the a...

Page 154: ...neto GO TO point 5 Specific tooling 020481Y Control unit interface wiring 5 Check the continuity of the connection lines of the sensor from the ECU to the flywheel connector 19 red lead Ohm continuity...

Page 155: ...hm YES point 11 NO point 10 10 Restore the insulation or replace the wiring GO TO point 9 11 Check the line positive insulation 1 19 0V 1 20 0V YES point 13 NO point 12 N B THE CHECK SHOULD BE PERFORM...

Page 156: ...15 Check the phase rpm sensor resistance 19 20 Ohm at 20 detected 106 7W YES point 17 NO point 16 N B IF THE CHECK IS DONE WHEN THE ENGINE IS HOT RESISTIVE VALUES WILL BE HIGHER 16 When out of toleran...

Page 157: ...e 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 20 20 If voltages are very different replace the ECU GO TO point 19 21 The phase rpm sensor and relevant cir...

Page 158: ...nition is managed based on two pa rameters Ignition lead Dwell time The ignition lead curve is optimised based on the rpm and engine load perceived by the TPS1 and TPS2 sensors The dwell time is optim...

Page 159: ...possible use an external spark plug and check the 5 sparks directly YES point 3 NO point 4 NO point 5 3 There are 5 sparks The ignition system is working For greater certainty continue with the auto...

Page 160: ...voltage YES 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 See ECU sup...

Page 161: ...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...

Page 162: ...V 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...

Page 163: ...k 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 2...

Page 164: ...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 B...

Page 165: ...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 plac...

Page 166: ...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 pressur...

Page 167: ...the injector is called an air injector even if a mixture of air and petrol is actually injected Direct injection of petrol transported by the compressed air makes it possible to obtain a fine mist of...

Page 168: ...ircuit are currently efficient For greater certainty continue with the auto diag nostic check in order to highlight stored errors 4 The injector has not been enabled and the tester has returned test f...

Page 169: ...oint 11 13 Check the continuity of the air injector control line 13 pink injector connector continuity YES point 15 NO point 14 N B THIS CONNECTOR ALLOWS AN EASY CHECK USING THE MULTIMETER PRODS DO NO...

Page 170: ...r 1MOhm YES point 23 NO point 22 22 Replace the air injector GO TO point 21 23 Connect the specific tool to the ECU Connect the air injector connector Check the presence of voltage to the ECU 1 13 V b...

Page 171: ...dle at 60 C The values are indicative but useful for diagnostics Command failures or unusual opening times are always caused by the ECU fuel pump circuit TERMINALS 1 14 CONDITIONS Switch in ON positio...

Page 172: ...rrent motor It is designed to distribute high pressure with small deliveries and little absorption thus suited for use on reduced horse power en gines Given the reduced absorption the pumped is powere...

Page 173: ...at the pump entrance with with the derivation of two tubes respectively A fuel arrival tube B fuel drainage tube In the case of replacement do not invert the order of the two tubes during reassembly...

Page 174: ...ecific tooling 020460Y Scooter diagnosis and tester 12 No error present The pump s electric command circuit is efficient For a more complete check proceed with the check on the fuel supply circuit 13...

Page 175: ...l pump control line positive in sulation 1 14 0V YES point 22 NO point 21 21 Restore the wiring GO TO point 20 22 Check the fuel pump control line negative in sulation 1 14 1 MOhm YES point 24 NO poin...

Page 176: ...bsorption but the pump does not rotate Replace the pump due to mechanical damage GO TO point 24 28 Especially in case an error is verified in the occurred or stored state repeat activation of the pump...

Page 177: ...jector The petrol injector receives pressurised fuel through the supply system The ECU runs the injector by checking the time and opening time The fuel is injected into the compressed air chamber this...

Page 178: ...O 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 cert...

Page 179: ...COOLANT TEMPERATURE SENSOR Specification Desc Quantity 1 Digital instrument unit 2 Key switch contacts 3 Fuse 5A 4 Fuse 20A 5 Battery 12V 9Ah 6 Injection ECU 7 Coolant temperature sensor NRG Power Pu...

Page 180: ...pure jet injection NRG Power Purejet INJ PJ 64...

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

Page 182: ...IME THE CALLIPER IS SERVICED Insert the following sealing rings 1 2 pistons 3 locate the OR seal inside a calliper body 4 Join the inner and outer bodies via fixing bolts Refit the pads and breathe an...

Page 183: ...Locking torques N m Brake fluid tube calliper 20 25 Nm Fastening screws calliper to the crankcase 20 25 Oil bleed screw 7 to 10 Nm Front brake disc Removal Remove the front wheel loosening the axle c...

Page 184: ...properly The protrusion measured near the external edge of the disc must be less than 0 1 mm If a value is measured other than the specified value remove the front wheel Front Rear Suspension chapter...

Page 185: ...attention in re covering the spring hence remove the pads The pads must be replaced if the work ing thickness is less than 1 5 mm Refitting To reassemble perform the above steps in re verse order Pos...

Page 186: ...F 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 CH...

Page 187: ...the tube collecting the brake oil in a container On refitting perform the operation in reverse Tighten the hydraulic line to the prescribed torque and bleed the system Locking torques N m Brake fluid...

Page 188: ...SED 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 sh...

Page 189: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 190: ...m level then close the expan sion tank 6 Heat up the engine to normal operating tem perature in order to eliminate any air forma tion in the main lines 7 Stop the engine and let it cool then check tha...

Page 191: ...in the picture With the aid of the special tool loosen the impel ler shaft turning the spanner clockwise left hand ed thread As the thread is fully disengaged extract the shaft with the aid of pliers...

Page 192: ...020168Y Water seal punch mount on half crankcase 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...

Page 193: ...he head partially draining the system Remove the cylinder head Remove the two fixing screws and hence the thermostat Check 1 Visually check that the thermostat is not dam aged 2 Fill a metallic contai...

Page 194: ...tal multimeter 020151Y Air heater Characteristic Thermostat check Opening start temperature 60 2 C Refitting Refit the thermostat onto the head fol lowing the removal operations in the reverse order a...

Page 195: ...INDEX OF TOPICS CHASSIS CHAS...

Page 196: ...est and its side fair ings Remove the expansion tank and the fuel filler cap Remove the 11 fixing screws and hence release the knee guard See also Footrest Taillight assy Remove the top joining elemen...

Page 197: ...fairing from the foot rest by removing the two screws join ing this to the spoiler and the knee guard See also Frame central cover Frame central cover Side fairings Remove the top l h s and r h s fai...

Page 198: ...element located behind the taillight Remove the 2 screws joining the top side fairings Remove the 4 lower screws joining the front wheel housing cover with the low er side fairings See also Side fairi...

Page 199: ...ing the tank to the frame and lower the tank so to disconnect the inlet and outlet fuel hoses from the pump Remove the tank completely paying at tention to avoid fuel spillage See also Footrest Front...

Page 200: ...Chassis NRG Power Purejet CHAS 6...

Page 201: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 202: ...andlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam low beam position and parking lights and the respective warning li...

Page 203: ...ND 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 FR...

Page 204: ...R EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functi...

Page 205: ...INDEX OF TOPICS TIME TIME...

Page 206: ...devoted to the time necessary to carry out repairs The description and code for each operation is in dicated Engine ENGINE Code Action Duration 1 001001 Engine to chassis Replace ment Time NRG Power...

Page 207: ...Crankcase CRANKCASE Code Action Duration 1 001133 Engine crankcase Replace ment NRG Power Purejet Time TIME 3...

Page 208: ...NKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001118 Main bearings Replacement 3 001099 Oil seal flywheel side Re placement 4 001100 Oil seal clutch side Re placement Time NRG Power P...

Page 209: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder piston Replace ment 2 001107 Cylinder piston Inspection cleaning NRG Power Purejet Time TIME 5...

Page 210: ...057 Thermostat Replacement 4 001093 Spark plug Replacement 5 001126 Head Replacement 6 007010 Bleed valve Replacement 7 001178 Disc pack Replacement 8 001083 Thermistor Replacement 9 005111 Air inject...

Page 211: ...ulley DRIVEN PULLEY Code Action Duration 1 001110 Driven pulley Replacement 2 001022 Clutch Replacement 3 001155 Clutch bell housing Re placement 4 001012 Driven pulley overhaul NRG Power Purejet Time...

Page 212: ...Oil pump OIL MIX PUMP Code Action Duration 1 001018 Mixer Replacement 2 001019 Mixer belt replacement 3 001028 Mix movement gear socket Replacement Time NRG Power Purejet TIME 8...

Page 213: ...EDUCTION GEAR Code Action Duration 1 001010 Geared reduction unit Serv ice 2 001156 Gear reduction unit cover Replacement 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replace ment NRG Po...

Page 214: ...on Duration 1 001011 Driving belt Replacement 2 001066 driving pulley Replacement 3 001017 Starter sprocket wheel Re placement 4 001086 Driving half pulley replace 5 001177 Variator rollers shoes Re p...

Page 215: ...1 001096 Transmission crankcase cov er Replacement 2 001131 Transmission air intake Re placement 3 001132 Transmission air inlet pipe Replacement 4 001135 Transmission cover bearing Replacement 5 0041...

Page 216: ...pump WATER PUMP Code Action Duration 1 001113 Water pump Replacement 2 001062 Water pump command shaft Replacement 3 007019 Connection water pump pipe return pipe Replace ment Time NRG Power Purejet T...

Page 217: ...tarter motor STARTER MOTOR Code Action Duration 1 001020 Starter motor Replacement 2 005045 Starter motor cable harness Replacement 3 001017 Start up pinion Replace ment NRG Power Purejet Time TIME 13...

Page 218: ...heel magneto FLYWHEEL MAGNETO Code Action Duration 1 001058 Flywheel Replacement 2 001067 Stator Replacement 3 001173 Rotor Replacement 4 001087 Flywheel cover Replace ment Time NRG Power Purejet TIME...

Page 219: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body 2 001171 Throttle body Overhaul 3 004122 Air cleaner carburettor fitting Replacement NRG Power Purejet Time TIME 15...

Page 220: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001136 Exhaust emissions Adjust ment Time NRG Power Purejet TIME 16...

Page 221: ...Air cleaner AIR PURIFIER Code Action Duration 1 001027 Body air cleaner union Re placement 2 001015 Air filter box Replacement 3 001014 Air filter Replacement cleaning NRG Power Purejet Time TIME 17...

Page 222: ...uration 1 001053 Stand bolt Replacement 2 004004 Stand Replacement 3 004001 Frame replace 4 004015 Footrest Replacement 5 004171 Stand support plate Re placement 6 004143 Footrest support replace Time...

Page 223: ...ction Duration 1 004065 Front shield rear section Re placement 2 004064 Front shield Replacement 3 003087 Wheel housing Replace ment 4 004167 Grill radiator cover Re placement 5 004176 Air vent Replac...

Page 224: ...Side fairings CENTRAL COVER Code Action Duration 1 004053 Spoiler Replacement 2 004178 Footrest Replacement 3 004011 Central chassis cover Re placement Time NRG Power Purejet TIME 20...

Page 225: ...eat compartment HELMET COMPARTMENT Code Action Duration 1 004059 Spark plug inspection flap Replacement 2 004016 Helmet compartment Re placement 3 005046 Battery cover change NRG Power Purejet Time TI...

Page 226: ...ration 1 005022 Rear turn indicators Re placement 2 005068 Rear turn indicator bulb Re placement 3 005005 Taillight Replacement 4 005023 Rear tail light support Re placement 5 005091 Turn indicator gl...

Page 227: ...Mudguard MUDGUARDS Code Action Duration 1 004009 Rear mudguard Replace ment 2 004052 Bumper Replacement 3 004002 Front mudguard Replace ment NRG Power Purejet Time TIME 23...

Page 228: ...eplacement 2 005010 Tank float Replacement 3 004011 Central chassis cover Re placement 4 004072 Fuel filter Replacement 5 004110 Fuel tank hose Replace ment 6 004168 Fuel tank cap Replacement 7 004170...

Page 229: ...ANK Code Action Duration 1 004017 Oil reservoir Replacement 2 005018 Oil reservoir float Replace ment 3 004095 Oil reservoir cock Replace ment 4 004091 Oil reservoir hose Replace ment NRG Power Pureje...

Page 230: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorbers Re placement Time NRG Power Purejet TIME 26...

Page 231: ...rings STEERING FIFTH WHEELS Code Action Duration 1 003002 Steering fifth wheel Re placement 2 003073 Steering clearance Adjust ment 3 004119 Bearing upper steering fifth wheel Replacement NRG Power Pu...

Page 232: ...3059 Counterweight Replace ment 6 002024 Front brake pump replace 7 002037 Brake or clutch lever Re placement 8 002047 Front brake fluid and air bleeding system Replace ment 9 003061 Accelerator trans...

Page 233: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine frame swinging arm fitting Replacement NRG Power Purejet Time TIME 29...

Page 234: ...Seat SEAT Code Action Duration 1 004003 Saddle Replacement 2 004054 Seat lock hook Replace ment 3 002083 Saddle opening transmission Replacement Time NRG Power Purejet TIME 30...

Page 235: ...T AND HANDLEBAR COVER Code Action Duration 1 005014 Odometer Replacement 2 004018 Handlebar front section Re placement 3 004019 Handlebar rear section Re placement 4 005078 Odometer glass Replace ment...

Page 236: ...LIGHT Code Action Duration 1 005067 Front turn indicator bulb Re placement 2 005008 Front headlamp bulbs Re placement 3 005002 Front headlamp change 4 005012 Front turn indicator Re placement Time NR...

Page 237: ...t wheel axle Replace ment 7 005089 Tone wheel Replacement Grease tone wheel or drive Please take note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mistake the codes 002...

Page 238: ...1 Drive 2 Tone wheel Rear wheel REAR WHEEL Code Action Duration 1 001071 Rear wheel rim replace 2 001016 Rear wheel Replacement 3 002070 Rear brake disc Replace ment 4 004126 Rear wheel tyre Replace...

Page 239: ...compressore aria AIR COMPRESSOR Code Action Duration 1 001168 Air compressor Replace ment 2 004160 Compressed air hose Re placement NRG Power Purejet Time TIME 35...

Page 240: ...Fuel pump Replacement 2 004137 Injector pump pipe Replace ment 3 004086 Petrol pump depression tube Replacement 4 004072 Fuel filter Replacement 5 004138 Fuel reverse pipe Replace ment 6 001048 Injec...

Page 241: ...01023 Control unit Replacement 2 001094 Spark plug cap Replace ment 3 005001 Electrical system Replace ment 4 005009 Voltage regulator replace 5 005136 Resistance Replacement 6 005044 Front lights cab...

Page 242: ...ERY Code Action Duration 1 005007 Battery Replacement 2 005024 Battery fuse Replacement 3 005025 Fuse holder Replacement 4 005011 Start up remote control switch Replacement Time NRG Power Purejet TIME...

Page 243: ...Replacement 2 005040 Horn button Replacement 3 005016 Key switch Replacement 4 004096 Lock series Replacement 5 004010 Antitheft lock replace 6 005003 Horn Replacement 7 005006 Light switch or turn in...

Page 244: ...002012 Splitter Replacement 2 002058 Mix splitter transmission complete Replacement 3 002057 Carburettor splitter trans mission complete Replace ment 4 002054 Throttle or splitter transmis sion comple...

Page 245: ...t brake pads Replace ment 2 002021 Front brake piping Replace ment 3 002039 Front brake calliper Re placement 4 002002 Rear brake pads Replace ment 5 002020 Rear brake disc piping Re placement 6 00204...

Page 246: ...Action Duration 1 004159 Plates Stickers Replace ment 2 004056 Upper rear light cover Re placement 3 004036 Lower chassis cover Re placement 4 004085 Fairing 1 Replacement 5 004129 Rear fairing Replac...

Page 247: ...suspension FORK Code Action Duration 1 003010 Front suspension Service 2 003051 Complete fork replace 3 003048 Fork oil seal Replacement 4 003041 Fork stanchion Replace ment NRG Power Purejet Time TI...

Page 248: ...7002 Water cooler Replacement 3 001052 Coolant and air bleed Re placement 4 007024 Expansion tank cap Re placement 5 007013 Expansion tank radiator connecting hose Replace ment 6 007003 Delivery line...

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