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VESPA GT 200, Workshop Manual

The VESPA GT 200 Workshop Manual is the ultimate guide for owners looking to maintain and repair their beloved scooter. This comprehensive manual, available for free download at manualshive.com, provides detailed instructions, diagrams, and troubleshooting tips, ensuring hassle-free ownership and optimal performance of your VESPA GT 200.

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163 

10.10.14  Removing the Valves 

-  

Using the appropriate special tool, fitted with the 
adapter  shown  in  the  figure,  remove  the  split 
cones, the valve spring retainer caps, the  valve 

springs and the valves themselves. 

Special tools and equipment: 

 

Valve removing tool 

020382Y 

Adapter 

020382/11Y 

Warning

  –  Place  the  valves  so  as  to  recognize 

their original position on the head. 

 

-  

Remove  the  valve  seals  with  the  appropriate 
special tool. 

Special tools and equipment: 

 

Oil seals removing tool 

020431Y 

-  

Remove the spring seats. 

 

 

10.10.15  Removing the Cylinder and Piston Assembly 

-  

Remove the chain guide. 

-  

Remove the cylinder base gasket. 

Warning

  –  Ensure  the  piston  is  well-supported 

whilst  removing  the  cylinder,  in  order  to  avoid 

damaging it. 

 

Summary of Contents for GT 200

Page 1: ......

Page 2: ... Dimensions 19 2 4 Engine 20 2 4 1 General 20 2 4 2 Walbro carburetor 21 2 4 3 Kehin carburetor 22 2 5 Transmission 23 2 6 Capacities 23 2 7 Electrical Components 23 2 8 Frame Suspensions Brakes and Tires 24 2 8 1 Frame and Suspension 24 2 8 2 Brakes 24 2 8 3 Wheels and Tires 24 3 Tightening Torques 25 3 1 Steering Unit 25 3 2 Frame 25 3 3 Front Suspension 25 3 4 Front Brake 26 3 5 Rear Suspension...

Page 3: ... Special Tools 37 6 1 Steering Bearing Seat Installer 001330Y 37 6 2 Pliers 001467Y014 37 6 3 Bell 001467Y017 37 6 4 Steering Column Ball Cage Bearing Removing Punch 020004Y 37 6 5 Front Suspension Overhaul Tool 020021Y 38 6 6 Punch 020036Y 38 6 7 Punch 020038Y 38 6 8 Ring Nut Spanner 020055Y 38 6 9 Crankshaft Aligner 020074Y 39 6 10 Heat Gun Support 020150Y 39 6 11 Heat Gun 020151Y 39 6 12 Oil Pr...

Page 4: ...Y 44 6 29 Handle 020376Y 44 6 30 Valve Half Cone Remover 020382Y44 6 31 Bushing 020382Y011 44 6 32 Piston Assembly Band 020393Y 45 6 33 Multimeter Adapter 020409Y 45 6 34 Guide 15 mm 020412Y 46 6 35 Clutch Drum Lock Wrench 020423Y46 6 36 Punch 020424Y 46 6 37 Punch 020425Y 46 6 38 Piston Fitting Fork 020426Y 47 6 39 Piston Support 020428Y 47 6 40 Valve O Ring Remover 020431Y 47 6 41 Oil Pressure G...

Page 5: ... Air Filter 56 7 5 Engine Oil 58 7 5 1 Checking the Engine Oil Level 58 7 5 2 Topping Up the Engine Oil 59 7 5 3 Replacing the Oil and Oil Filter 59 7 6 Hub Oil 61 7 6 1 Checking the Hub Oil Level 61 7 6 2 Replacing the Hub Oil 61 7 7 Topping Up the Engine Cooling Liquid 62 7 8 Brake Fluid 63 7 8 1 Checking the Brake Fluid Level 63 7 8 2 Topping Up the Brake Fluid Level 64 7 9 Removing the Steerin...

Page 6: ...rting Problems 80 8 1 7 Excessive Oil Consumption Excessive Smoke from Exhaust 81 8 1 8 Insufficient Lubrication Pressure 81 8 1 9 Engine Tends to Cut Out at Full Throttle 82 8 1 10 Engine Tends to Stop at Idle 82 8 1 11 Excessive Fuel Consumption 83 8 2 Transmission and Brakes 83 8 2 1 Irregular Clutch Operation or Grapping 83 8 2 2 Poor Braking Performance 84 8 2 3 Brakes Overheating 84 8 3 Elec...

Page 7: ...ic Ignition System97 9 2 3 Diagnostic Codes 98 9 2 4 2 Flash Diagnostic Code 98 9 2 5 3 Flash Diagnostic Code 99 9 2 6 Ignition System 99 9 2 7 Spark Plug Power Supply Failure 100 9 2 8 Battery Charging System 101 9 2 9 Checking the Voltage Regulator 102 9 2 10 Stator check 102 9 2 11 Checking the Regulator 103 9 2 12 Checking the Automatic Choke Section 103 9 2 13 Turn Signal Lights Fail to Opera...

Page 8: ...he Driven Pulley Shaft Bearing 119 10 7 6 Removing the Belt Support Roller120 10 7 7 Refitting the Belt Support Roller 120 10 7 8 Removing the Driving Pulley 121 10 7 9 Removing the Driven Pulley 121 10 7 10 Inspecting the Clutch Drum 122 10 7 11 Checking the Clutch Drum Surface Eccentricity 122 10 7 12 Removing the Clutch 123 10 7 13 Disassembling the Fixed Driven Half Pulley Bearings 123 10 7 14...

Page 9: ... 10 7 32 Checking the Hub Cover 136 10 7 33 Fitting the Hub Casing Bearings 136 10 7 34 Fitting the Wheel Axle Bearing on the Cover 137 10 7 35 Checking the Hub Shafts 138 10 7 36 Fitting the Hub Gears 139 10 7 37 Fitting the Hub Cover 139 10 8 Flywheel 140 10 8 1 Removing the Flywheel Cover Assembly 140 10 8 2 Removing the Flywheel 143 10 8 3 Removing the Stator 144 10 8 4 Checking the Stator 144...

Page 10: ...the Camshaft and Rockers 161 10 10 13 Removing the Cylinder Head 162 10 10 14 Removing the Valves 163 10 10 15 Removing the Cylinder and Piston Assembly 163 10 10 16 Inspecting the Small End 164 10 10 17 Inspecting the Wrist Pin Diameter165 10 10 18 Inspecting the Piston and Cylinder Diameters 165 10 10 19 Inspecting the Piston 166 10 10 20 Checking the Piston Ring Gap 167 10 10 21 Fitting the Pis...

Page 11: ...the Crankcase Halves 186 10 11 5 Checking the Main Bearings 187 10 11 6 Assembling the Crankcase Halves 188 10 11 7 Fitting the Starter Motor 190 10 11 8 Removing the Carburetor 191 10 11 8 1 Kehin CVK 30 Carburetor 191 10 11 8 2 Walbro WVF 7P Carburetor 197 10 11 9 Re assembling the carburetor 204 10 11 9 1 Kehin CVK 30 Carburetor 204 10 11 9 2 Walbro WFV 7P Carburetor 206 10 11 10 Checking the F...

Page 12: ...he Front Brake Caliper Shock Absorber Bracket 232 11 7 Front Brake Caliper Shock Absorber Bracket Overhaul 233 11 8 Removing the Front Shock Absorber235 11 9 Front Swing Arm Overhaul 235 11 10 Steering Column Ball Cage Bearings Overhaul 237 11 11 Removing the Rear Shock Absorber Silencer Bracket 240 11 12 Rear Shock Absorbers 241 11 12 1 Removing the Rear Shock Absorbers 241 11 12 2 Refitting the ...

Page 13: ...Fuel Tank 258 12 15 Removing the Radiators and the Cooling Fan 260 12 16 Removing the Rear Mudguard 261 12 17 Removing the Turn Signal Lights 261 12 18 Removing the Electrical Opening Seat System 262 13 Pre Delivery Inspections 264 13 1 Checking the Vehicle Appearance 264 13 2 Checking the Tightening Torques 264 13 3 Checking the Electrical Circuit 264 13 4 Checking the Levels 265 13 5 Road Test 2...

Page 14: ...2 14 17 Flywheel Magneto 273 14 18 Carburetor 273 14 19 Air Filter 274 14 20 Silencer 274 14 21 Frame 275 14 22 Central Stand 275 14 23 Footrest and Battery 276 14 24 Glove Box 276 14 25 Helmet Compartment and Rear Fender 277 14 26 Front Fender and Rear Mudguard 277 14 27 Fuel Tank 277 14 28 Cooling System 278 14 29 Fuel Pump 278 14 30 Steering Column 279 14 31 Front Suspension 279 14 32 Rear susp...

Page 15: ... 37 Saddle and Rear Rack 283 14 38 Locks and Immobilizer 283 14 39 Mirrors Electric Controls and Instrument Panel 284 14 40 Lights 285 14 41 Electrical Devices 286 14 42 Front Wheel 287 14 43 Rear Wheel 287 ...

Page 16: ...s of mechanics and standard procedures required for general vehicle repair therefore information regarding routine procedures has been deliberately omitted Any relevant changes concerning the vehicle characteristics or specific repair operations will be divulged in the form of updates to this manual Satisfactory repair or service cannot be achieved without the necessary equipment and tools Refer t...

Page 17: ...tilated area aiming compressed air so as to avoid inhaling the dust produced by wear in the friction material Even the dust from asbestos free linings can damage the health 2 1 2 Service Recommendations Use g enuine Piaggio spare parts and recommended lubricants Use of non genuine spare parts may damage the vehicle For operations requiring special tools use only those designed specifically for thi...

Page 18: ...18 2 2 Vehicle Identification 2 2 1 Frame No Vehicle Frame prefix Granturismo 200 cc ZAPM3120000001001 2 2 2 Engine No Vehicle Engine prefix Granturismo 200 cc M312M1001 ...

Page 19: ...al Specifications 2 3 1 Weight and Dimensions Characteristics Descriptions Dry weight 308 lbs 140 Kg Width at handgrips 2 48 ft 755 mm Length 6 36 ft 1 940 mm Wheel base 4 58 ft 1 395 mm Saddle height 2 62 ft 800 mm ...

Page 20: ...H 3 arm rockers with threaded adjuster Bore 2 83 in 72 0 mm Stroke 1 91 in 48 6 mm Piston displacement 12 06 cu in 197 775 cm3 Compression ratio 11 12 1 Walbro carburetor WVF 7P Keihin carburetor CVK 30 Engine idle 1650 50 rpm CO value 3 8 0 7 Air filter Sponge air filter soaked in fuel oil mixture 50 gasoline 50 oil Starter system Electric starter motor with torque limiter ...

Page 21: ...ax jet 95 Slow running jet 33 Main air jet 120 Idling air jet 55 Throttle valve spring 0 264 lbs 1 18 N Initial opening of idle speed mixture adjusting screw 2 Conical needle 495 Notches from top of conical needle 2 Diffuser nozzle Ø 0 106 in 2 7 mm Fuel inlet hole Ø 0 059 in 1 5 mm Starting air jet 200 Starting diffuser jet 110 Starter jet 45 Starter pin diameter Ø 0 070 in 1 78 mm Starter device...

Page 22: ...of idle speed mixture adjusting screw 2 Conical needle NDAA Notches from top of conical needle Single notch needle Diffuser nozzle Ø 1 969 in 5 0 mm Fuel inlet hole Ø 0 059 in 1 5 mm Starting air jet Starting diffuser jet Starter jet 42 Choke pin diameter Choke device resistance 20 O Venturi tube Ø 1 142 in 29 0 mm 47 30 9 mm Throttle valve Ø 1 201 in 30 5 mm Tube maximum choke The identification ...

Page 23: ...l tank including reserve 0 5 gal 2 5 gallons 9 5 liters Rear hub 0 16 quarts 150 cm3 recommended oil TUTELA ZC 90 Cooling system fluid 0 55 0 57 gallons 2 10 2 15 liters recommended PARAFLU 11FE diluted 2 7 Electrical Components Characteristics Descriptions Ignition type Electronic ignition by capacitive discharge with variable advance and separate H T coil Variable ignition advance before T D C F...

Page 24: ... 8 2 Brakes Characteristics Descriptions Front Ø 8 66 in 220 mm disc and hydraulically operated floating caliper via RH lever with two Ø 0 98 in 25 mm pistons Rear Ø 8 66 in 220 mm disc and hydraulically operated floating caliper via LH lever with two Ø 1 18 in 30 mm pistons 2 8 3 Wheels and Tires Characteristics Descriptions Aluminum alloy rims Front 3 00 12 Rear 3 00 12 Tires Front 120 70 12 Tub...

Page 25: ...e Component Qty Torque lbs ft N m Swing arm engine pivot nut 1 47 1 53 0 64 72 Swing arm frame pivot nut 1 56 0 61 1 76 83 Frame engine link nut 1 24 3 30 2 33 41 Silent block support plate bolt 2 30 9 38 3 42 52 Center stand bolt 1 18 4 22 1 25 30 3 3 Front Suspension Component Qty Torque lbs ft N m Shock absorber plate caliper fixing screw 2 14 7 19 9 20 27 Wheel axle nut 1 55 2 66 3 75 90 Wheel...

Page 26: ...12 16 Pad clamping pin 2 13 6 18 4 19 6 25 Brake pump basin screw 2 9 6 13 7 15 20 3 5 Rear Suspension Component Qty Torque lbs ft N m L H side shock absorber support plate crankcase fixing screw 2 13 7 18 4 20 25 Shock absorber top fastening 2 13 7 18 4 20 25 Shock absorber bottom fastening 2 24 3 30 2 33 41 Rear wheel axle 1 76 5 92 6 104 126 Wheel hub fixing screw 5 13 7 18 4 20 25 Silencer sho...

Page 27: ...ake pump basin screw 2 11 0 14 7 15 20 Caliper coupling screw 2 22 1 24 3 30 33 3 7 Silencer Component Qty Torque lbs ft N m Silencer heat shield fixing screw 4 3 7 4 4 5 6 Exhaust gas inlet screw 1 9 6 11 0 13 15 Silencer support arm fixing screw 3 13 7 18 4 20 25 3 8 Hydraulic Components Component Qty Torque lbs ft N m Hub oil bleeder cap 1 11 0 12 5 15 17 Oil filter crankcase fixing screw 1 19 ...

Page 28: ...4 3 9 Cylinder Head Component Qty Torque lbs ft N m Spark plug 1 8 8 10 3 12 14 Head cover screw 5 4 4 5 2 6 7 Head cylinder fixing nut 4 5 2 0 7 rotation 7 1 180 Head fixing side screw 2 8 1 9 6 11 13 Start up mass screw 1 5 2 6 3 7 8 5 Adjustment tappet lock nut 2 4 4 5 9 6 8 Intake manifold screw 2 8 1 9 6 11 13 Timing chain tightening sliding block screw 1 7 4 10 3 10 14 Start up mass bell scr...

Page 29: ...crew 13 8 1 9 6 11 13 Driven pulley axle nut 1 39 8 44 4 54 60 Rear hub cover screw 7 17 7 19 9 24 27 3 11 Flywheel Component Qty Torque lbs ft N m Flywheel cover fixing screw 4 3 7 4 4 5 6 Stator unit screw 2 2 2 2 9 3 4 Flywheel nut 1 38 3 42 7 52 58 Pick up fixing screw 2 2 2 2 9 3 4 3 12 Engine Crankcase and Shaft Component Qty Torque lbs ft N m Engine crankcase inside head screws transmission...

Page 30: ...11 13 Crankcase timing chain cover screw 3 2 5 3 2 3 5 4 5 3 13 Cooling Component Qty Torque lbs ft N m Water pump impeller cover 3 2 2 2 9 3 4 Water pump impeller driving joint screws 3 2 2 2 9 3 4 Thermostat cover screws 2 2 2 2 9 3 4 ...

Page 31: ...5 71 990 71 997 2 8327 2 8330 71 953 71 960 Cylinder 0003 0 0007 0 835 2 0 010 0 018 72 00 B 2 8345 2 8347 71 997 72 004 2 8330 2 8333 71 960 71 967 C 2 8347 2 8350 72 004 72 011 2 8333 2 8336 71 967 71 974 Piston 0005 0 833 2 014 0 97 71 D 2 8350 2 8353 72 011 72 018 2 8336 2 8338 71 974 71 981 0 00118 0 00173 0 030 0 044 1 3 in 33mm 1 3 in 33mm ...

Page 32: ...t Dimensions Clearance Class Assembly Clearance Compression ring 2 834 0 059 72 0 1 5 A 0 005 0 011 0 15 0 30 Scraper ring 2 834 0 039 72 0 1 0 A 0 007 0 015 0 20 0 40 Scraper ring 2 834 0 098 72 0 2 5 A 0 007 0 015 0 20 0 40 ...

Page 33: ...to the measure A taken Note The A value to be measured is referred to the piston recess It indicates the amount by which the surface formed by the piston crown lowers compared to the surface formed by the cylinder upper part The more the piston descends into the cylinder the less the base gasket to be applied to recover the compression ratio will be and vice versa in mm Measure A Gasket thickness ...

Page 34: ... in mm Part Dimensions Clearance Class Assembly Clearance Half shaft transmission side 0019 0 0000 0 653 0 0 050 0 000 16 60 A Half shaft flywheel side 0019 0 0000 0 653 0 0 050 0 000 16 60 B Connecting rod 0040 0 0059 0 708 0 0 100 0 150 18 00 C Spacing tool 0000 0 0010 0 023 2 0 100 0 150 18 00 D D 0 007 0 019 0 20 0 50 ...

Page 35: ... 1 2978 32 953 32 963 A type Red B type Blue C type Yellow Half crankshaft bearing 0 0776 0 0777 1 970 1 973 0 0777 0 0778 1 973 1 976 0 0778 0 779 1 976 1 979 Half crankcase Half crankshaft Bearing Cat 1 Cat 1 B Cat 2 Cat 2 B Cat 1 Cat 2 A Note Spare crankcases are selected with half crankcases of the same category and mounted with category B bearings blue colored Match the shaft with two categor...

Page 36: ...Engine oil SAE 5W 40 synthetic oil exceeding API SJ specifications SELENIA HI Scooter 4 Tech Brake fluid Synthetic fluid SAE J1703 NHTSA 116 DOT 4 ISO 4925 TUTELA TOP 4 Coolant Monoethylene glycol based anti freezer CUNA NC 956 16 PARAFLU 11 FE Diluted Grease for driven pulley shaft compensating ring and moveable driven pulley sliding seat Molybdenum disulphide grease MONTBLANC MOLYBDENUM GREASE 4...

Page 37: ...0Y010 For top housing NECESSARY 001330Y 6 2 Pliers 001467Y014 Description Notes Part No 0 59 in 15mm Pliers NECESSARY 001467Y 014 6 3 Bell 001467Y017 Description Notes Part No Bell NECESSARY 001467Y 017 6 4 Steering Column Ball Cage Bearing Removing Punch 020004Y Description Notes Part No Punch for removing steering column ball cage bearings from steering head RECOMMENDED 020004Y ...

Page 38: ...spension overhaul tool NECESSARY 020021Y 6 6 Punch 020036Y Description Notes Part No Punch NECESSARY 020036Y 6 7 Punch 020038Y Description Notes Part No Punch NECESSARY 020038Y 6 8 Ring Nut Spanner 020055Y Description Notes Part No Steering column ring nut spanner NECESSARY 020055Y ...

Page 39: ... 6 10 Heat Gun Support 020150Y Description Notes Part No Metabo hg 1500 2 hot air gun support RECOMMENDED 020150Y 6 11 Heat Gun 020151Y Description Notes Part No Metabo hg 1500 2 hot air gun RECOMMENDED 020151Y 6 12 Oil Pressure Gauge 020193Y Description Notes Part No Oil pressure gauge NECESSARY 020193Y ...

Page 40: ...62Y 6 14 Half Pulley Assembler 020263Y Description Notes Part No Half pulley assembly sheath NECESSARY 020263Y 6 15 Fitting Punch 020306Y Description Notes Part No Retaining ring fitting punch NECESSARY 020306Y 6 16 Vacuum Pump 020329Y Description Notes Part No Mitivac like vacuum pump RECOMMANDED 020329Y ...

Page 41: ...iming light for two and four stroke engines RECOMMANDED 020330Y 6 18 Digital Multimeter 020331Y Description Notes Part No Digital multimeter RECOMMANDED 020331Y 6 19 Digital Tachometer 020332Y Description Notes Part No Digital tachometer RECOMMANDED 020332Y ...

Page 42: ...No Single battery charger RECOMMANDED 020333Y 6 21 Multiple Battery Charger 020334Y Description Notes Part No Multiple battery charger RECOMMANDED 020334Y 6 22 Dial Gauge 020335Y Description Notes Part No Dial gauge 0 001 mm with magnetic stand RECOMMANDED 020335Y ...

Page 43: ...ter NECESSARY 020359Y 6 24 Adapter 52 55 mm 020360Y Description Notes Part No 52 55 mm Adapter NECESSARY 020360Y 6 25 Guide 20 mm 020363Y Description Notes Part No 20 mm guide NECESSARY 020363Y 6 26 Guide 25mm 020364Y Description Notes Part No 25 mm guide NECESSARY 020364Y ...

Page 44: ...75Y Description Notes Part No 28 30 mm adapter NECESSARY 020375Y 6 29 Handle 020376Y Description Notes Part No Handle for adapters NECESSARY 020376Y 6 30 Valve Half Cone Remover 020382Y Description Notes Part No Tool for valve half cone removal NECESSARY 020382Y 6 31 Bushing 020382Y011 Description Notes Part No ...

Page 45: ...ARY 020382Y 011 6 32 Piston Assembly Band 020393Y Description Notes Part No Piston assembly band NECESSARY 020393Y 6 33 Multimeter Adapter 020409Y Description Notes Part No Multimeter adapter peak voltage measurement RECOMMENDED 020409Y ...

Page 46: ...h Drum Lock Wrench 020423Y Description Notes Part No Clutch drum lock wrench NECESSARY 020423Y 6 36 Punch 020424Y Description Notes Part No Driven pulley roller housing installing punch NECESSARY 020424Y 6 37 Punch 020425Y Description Notes Part No Oil seal flywheel side punch NECESSARY 020425Y ...

Page 47: ...Y 6 39 Piston Support 020428Y Description Notes Part No Piston projection support NECESSARY 020428Y 6 40 Valve O Ring Remover 020431Y Description Notes Part No Valve o ring removing tool NECESSARY 020431Y 6 41 Oil Pressure Gauge 020434Y Description Notes Part No Oil pressure gauge NECESSARY 020434Y ...

Page 48: ...ly NECESSARY 020439Y 6 43 Water Pump Overhaul Tool 020440Y Description Notes Part No Water pump overhaul tool NECESSARY 020440Y 6 44 Adapter 26 28 mm 020441Y Description Notes Part No 26 28 mm adapter NECESSARY 020441Y 6 45 Stop Wrench 020442Y Description Notes Part No Driving pulley wrench NECESSARY 020442Y ...

Page 49: ... 6 47 Guide 30 mm 020483Y Description Notes Part No 30 mm guide for hub bearing assembly NECESSARY 020483Y 6 48 Pivot Retainers Installer 020488Y Description Notes Part No Pivot retainers installation tool NECESSARY 020488Y 6 49 Hub Cover support 020489Y Description Notes Part No Hub cover support tool kit NECESSARY 020489Y ...

Page 50: ...tes Part No Engine support to be fitted with parts 002095Y015 Tube 002095Y022 Cross member 002095Y023 Nut 002095Y044 Plate 002095Y046 Clamp RECOMMENDED 002095Y 6 52 Pliers 002465Y Description Notes Part No Snap ring pliers RECOMMENDED 002465Y 6 53 Punch 06029Y Description Notes Part No Steering column ball cage bearing installing punch RECOMMENDED 006029Y ...

Page 51: ...51 6 54 Flywheel Extractor 08564Y Description Notes Part No Flywheel removing tool NECESSARY 008564Y 6 55 Gas Analyzer 494929 Description Notes Part No Exhaust gas analyzer RECOMMENDED 494929 ...

Page 52: ... V Secondary air filter external internal Clean Every 2 years Oil filter Replace S S S S S S S S S S S S S Valve clearance Check V V V V V Idle speed Adjust V V V V V V V Gas control Adjust V V V V V V V Variator rollers Check Replace V V V V V V V V V V V V Driving belt Check Replace V S V S V S V S V S V S Cooling fluid level Check V V V V V V V V V V V V Cooling fluid Replace Every 2 years Radi...

Page 53: ...ry Check V V V V V V V V V V V V V Headlight Check Adjust V V V V V V Tires pressure and wear Check V V V V V V V V V V V V Vehicle and braking system performance Road test V V V V V V V V V V V V V Labor time 70 130 135 140 150 90 245 90 150 140 135 90 260 Safety tightenings refer to the chapter Pre delivery Operations See rules ...

Page 54: ...hamber shows excessive signs of wear as to preclude the valve s regular seal or free sliding even if new Gaskets should be replaced every time the carburetor is reassembled Warning Fuel is highly explosive Always re place gaskets to prevent leakage 1 Diaphragm cover 2 Throttle valve spring 3 Conical needle support 4 Conical needle spring 5 Conical needle 6 Throttle valve diaphragm 7 Automatic chok...

Page 55: ...he insulator is in good conditions and no signs of cracks are visible Also check the condition of the seal washer and make sure that the electrodes are not worn out or excessively sooty Measure the spark gap with a suitable thickness gauge Standard dimension Spark gap 0 028 0 031 in 0 7 0 8 mm If necessary adjust the spark gap by carefully bending the side electrode If the spark plug shows any of ...

Page 56: ...air flow direction during normal engine operation Remove the left hand side fairing by releasing the two screws as shown in the figure Remove the helmet compartment Remove the three fastening screws that can be reached after the removal of the helmet compartment from inside the frame Remove the five fixing screws shown in the figure Remove the filtering element Replace the air filter with a new on...

Page 57: ...d air and wipe with a clean cloth Soak with a 50 fuel oil mixture use SELENIA AIR FILTER OIL Let the filtering element drip and squeeze it with hands without wringing Replace the filtering element Caution If the vehicle is mostly used on dusty roads the air filter must be cleaned more frequently than what indicated in the scheduled maintenance table Caution Never let the engine run without air fil...

Page 58: ... 7 5 1 Checking the Engine Oil Level Perform the following operations when the engine is cold Rest the vehicle on the central stand and on a flat surface Unscrew dipstick A dry it with a clean cloth and reinsert it by screwing it completely Remove the dipstick again and check that the level is between the MAX and MIN levels top up if required The MAX level mark means that in the engine there is an...

Page 59: ... once the engine has started Note Should the light turn on while braking idling or cornering check the oil level and the lubrication system as soon as possible 7 5 3 Replacing the Oil and Oil Filter Oil and filter should be replaced every 3 726 mi 6 000 km The engine should be emptied by draining the oil from the pre filter drainage tap B of the net pre filter on the flywheel side To facilitate th...

Page 60: ...650 cm3 of oil from cap A Subsequently start up the engine let it idle for a few minutes and then switch it off After about 5 minutes check the level and top up if necessary without ever exceeding the MAX mark The cartridge filter must be replaced every time the oil is changed For top ups and replacements use fresh Selenia HI Scooter 4 Tech oil Note Engine oil should be replaced when the engine is...

Page 61: ...nt of oil in the hub Reinsert the dipstick and screw it tightly The notches on the hub oil dipstick with the exception of the MAX mark refer to other PIAGGIO models and have no specific function as far as this vehicle is concerned 7 6 2 Replacing the Hub Oil Remove oil filler cap A Unscrew oil drain cap B and let the oil drain out completely Retighten the oil drain cap and then fill the hub with f...

Page 62: ...e vehicle s leg shield in order to access the cooling liquid expansion tank Remove the expansion tank cap and top up if the coolant level is below or near the MIN level in the expansion tank The fluid level should always be between the MIN and MAX marks The coolant consists of a 50 mixture of demineralized water and antifreeze solution with a base of ethylene glycol and corrosion inhibitors Warnin...

Page 63: ...ar In order to check the brake fluid level in the reservoirs follow these steps Rest the vehicle on its central stand on level ground and turn the handlebar to the central position Remove the brake pump cover Check the fluid level through the sight shown in the figure Note A certain decrease in the level of the fluid occurs as a result of pad wear ...

Page 64: ...ith water Warning The brake fluid is highly corrosive Do not let it come into contact with the paintworks Warning The brake fluid is hygroscopic i e it absorbs humidity from the surrounding air If the concentration of humidity in the fluid exceeds a certain value the braking action becomes insufficient Warning Never use braking fluid drawn from open or partly empty containers In normal climatic co...

Page 65: ...g the Steering Lock when on OFF Position Remove the leg shield as described in chapter Bodywork Remove the immobilizer antenna shown in the figure Disconnect the wiring Pull out the retaining spring shown in the figure and remove the ignition switch ...

Page 66: ...moving the Steering Lock when on LOCK Position The bolt retaining spring is not accessible in the LOCK position It is then necessary to drill the bolt as shown in the figure to eject it Note To refit the bolt from this position first disengage the steering lock by putting the lock body inner and outer part in the OFF position To refit proceed as described in the previous paragraph ...

Page 67: ...Trace a horizontal line on the screen 27 2 28 3 in 67 70 cm above ground Remove the steering cover by loosening the screw shown in the figure Switch on the headlight turn on the low beam and check that the horizontal line which separates the lighted area from the dark area is not above the line previously drawn on the screen To shift the headlight operate on the adjusting screw immediately below t...

Page 68: ... spark plug feeder cable 10 15 kO in series with the H T cable Remove the plastic cover from the slotted hole on the flywheel cover Using the lamp flash phase shift corrector align the reference mark on the flywheel cover with the level on the water pump drive Read the degrees of advance on the stroboscopic light Check the revolving speed corresponding to the degrees of advance in the tables below...

Page 69: ...rk Advance Variation Curve Rev limiter First threshold First threshold Tripping threshold 9 900 50 rpm 9 900 50 rpm Restore threshold 9 800 50 rpm 9 800 50 rpm Spark suppression 1 spark out of 7 2 sparks out of 3 ...

Page 70: ... 13 Evaporative emission system A Canister B Uni directional valve C Air intake membrane D Cylinder head E Carburetor F Air intake float chamber G Pump H Fuel output I Fuel tank L Plug M Fuel breather pipe ...

Page 71: ...ition Remove the side fairing and then the trans mission cooling air inlet duct so as to easily reach the flow adjustment screw Remove the gas cap on the exhaust Using the original washer install the exhaust gas collection kit onto the exhaust Suitably orientate all the components Close the gas outlet terminal of the tool Start the engine and let it warm up until the electric fan activates Stop th...

Page 72: ... value to 3 8 0 7 1 650 50 rpm Special equipment and tools Mityvac like vacuum pump 020329Y Digital tachometer 020332Y Exhaust gas analyzer 494929Y Note Check that the result is obtained with the gas valve in the closest position Also check that the carburetion adjustment is obtained with the flow screw open by 2 to 4 turns If not check the fuel level adjustment in the basin and check the fuel cir...

Page 73: ...ne is here replaced by a membrane The unit indicated by an arrow in the figure is provided with a cut off connected to the vacuum inlet on the intake manifold to shut the air inlet during deceleration to prevent explosions in the silencer 7 14 2 Description Air is sucked through hole A and flows through the first filter into hole B Passing through the hole indicated in the figure air reaches the s...

Page 74: ... 7 14 3 Removing the SAS Warning This operation must be performed with the engine cold Remove the silencer Remove the R H fairing Loosen the clamps and remove the cooling fluid inlet and outlet sleeves from the pump cover and drain the cooling system Remove the top strip fixing the SAS valve connection sleeve to the drainage as shown in the figure Remove the 2 fixing screws the gasket and the pipe...

Page 75: ...m the flywheel cover as shown in the figure Disconnect the vacuum pipe from the SAS valve Remove the pump support bracket and the fuel filter Remove the flywheel cover with the SAS valve by releasing the 4 hexagon screws as shown in the figure ...

Page 76: ... and flywheel cover causes an increase of noise of the system Carefully clean the internal and external filter If they exhibit damages or abnormal deformations proceed to the replacement Check that the sleeve connecting the secondary air to the head exhibits no cracks or deformations Replace them if necessary Check that the metal duct is free from cracks For re assembly perform the operations for ...

Page 77: ...l and oil recommended Selenia Air Filter Oil Squeeze the sponge without twisting allow it to drip and then replace it Automatic choke failure Check the mechanical sliding and the electrical connection and ensure that power is supplied Replace if necessary Clutch slipping Check and if necessary replace the clutch assembly and or the clutch drum housing Automatic transmission faulty Check correct pu...

Page 78: ...f the valve Level in float bowl too high Restore the level in the float chamber by bending the fuel inlet needle thrust blade on the float so that the float is parallel to the chamber surface when the carburetor is in an upside down position Automatic choke remains activated Check the correct sliding of the mechanical component and the electrical connection and ensure that power is supplied If nec...

Page 79: ... an up side down position Tank breather clogged Restore proper tank aeration Feed pipes choked or throttle Restore proper fuel flow Weak mixture Intake manifold cracked or clamps poorly tightened Replace the intake connection and check for any abnormal air leakage 8 1 5 Low Compression Symptom Possible Cause Operation Incorrect valve adjustment Adjust valve clearance Valves overheated Remove the c...

Page 80: ...g allow it to drip and then replace it Automatic choke failure Check the mechanical sliding and the electrical connection and ensure that power is supplied Replace if necessary Engine flooded Open the throttle wide and try to start the engine If the engine does not start remove the spark plug dry it and before replacing it crank the engine to expel the excess of fuel keeping the cap connected to t...

Page 81: ... ex cessive smoke from exhaust Valve guides worn Check and if necessary replace the head assembly 8 1 8 Insufficient Lubrication Pressure Symptom Possible Cause Operation Oil level too low Restore to the required level by topping up with fresh oil recommended oil Selenia HI Scooter 4 Tech Oil filter excessively dirty Replace the cartridge filter Oil pump play excessive Perform dimensional checks o...

Page 82: ... vacuum intake and the duct seal 8 1 10 Engine Tends to Stop at Idle Symptom Possible Cause Operation Idling jet dirty Wash in solvent and dry with compressed air Choke device remains activated Check electrical connections circuit continuity mechanical sliding and power supply replace if required Spark plug faulty or spark advance incorrect Replace the spark plug or check the ignition circuit comp...

Page 83: ...and idling jets are securely seated Excessive fuel consumption Float level Restore the level in the float chamber by bending the fuel inlet needle thrust blade on the float so that the float is parallel to the chamber surface when the carburetor is in an up side down position 8 2 Transmission and Brakes 8 2 1 Irregular Clutch Operation or Grapping Symptom Possible Cause Operation Clutch irregular ...

Page 84: ...orted Check the tightening of the brake disk screws Using a comparator and with the wheel mounted onto the vehicle measure the disk s axial deviation Poor braking performance Brake fluid leakage from the hydraulic system Replace faulty flexible connections piston or brake pump gaskets as necessary 8 2 3 Brakes Overheating Symptom Possible Cause Operation Defective piston sliding Check caliper and ...

Page 85: ...trol unit faulty With the ignition switch set to ON jumper contacts 1 Blue Black and 5 Red Blue on the electronic control unit connector If turn indicators do not light up and stay lit when the related switch is operated replace the regulator otherwise check the wiring and the switch 8 4 Steering Controls and Suspension 8 4 1 Excessive Steering Stiffness Symptom Possible Cause Operation Excessive ...

Page 86: ... of the ball bearings and of the related locknuts the rubber stops and the sliding bushes Also check the tightening torques of the wheel hub the brake caliper the disk and the shock absorber on the hub and steering column connections 8 4 4 Suspension Oil Leaking Symptom Possible Cause Operation Suspension oil leaking Faulty seal Replace the shock absorber Check the wear of the steering caps and ad...

Page 87: ...Saddle opening actuator 11 Voltage regulator 12 Rear left hand side turn signal light with bulb 13 Number plate light with bulb 14 Complete tail light with low beam bulb and 6 brake light bulbs 15 Rear right hand side turn signal light with bulb 16 Fuel level transmitter 17 Engine earth 18 Starter motor 19 Oil pressure sensor 20 Magneto flywheel 21 Automatic choke device 22 Thermostat 23 H T coil ...

Page 88: ...erve warning light oil pressure warning light upper beam indicator RH turn signal light indicator LH turn signal light indicator LED for immobilizer 3 bulbs for instrument illumination 34 Relay switch 35 Complete right or left hand asymmetric headlight with bulb for headlight and 1 bulb for position 36 Fuse holder box 37 Anti theft alarm fitting 38 Electronic ignition device CDI 39 Engine stop dev...

Page 89: ...89 9 1 Electrical Diagrams 9 1 1 Ignition Section 1 Pick up 5 Spark plug 2 Flywheel magneto 6 H T coil 3 15A Fuse No 7 7 Voltage regulator 4 Electronic ignition device CDI 8 12V 12Ah Battery ...

Page 90: ...90 9 1 2 Turn Signal Lights Horn Services and Accessory Pre Wiring ...

Page 91: ...ulbs 12V 10W 14 7 5A Fuse 4 Horn 12V 15 Anti theft alarm pre wiring 5 Saddle opening button 16 Radio intercom pre wiring 6 Horn button 17 10A Fuse 7 Turn signal lights switch 18 Immobilizer LED 8 Saddle opening actuator 19 Battery 12V 12Ah 9 7 5A Fuse 20 15A Fuse 10 7 5A Fuse 21 Immobilizer antenna 11 Anti theft alarm pre wiring 22 Electronic ignition device CDI ...

Page 92: ...d temperature indicator 7 Oil pressure sensor 2 Fuel level indicator 8 Fuse 7 5A 3 Fuel level transmitter 9 Key switch contacts 4 Thermostat 10 Battery 12V 12Ah 5 Fuel indicator 12V 1 2W 11 Fuse 15A 6 Oil pressure indicator 12V 1 2W 12 Electronic ignition device ...

Page 93: ...op deviator 8 No 8 bulbs for stop light 12V 2 3W 2 Key switch contacts 9 Fuse 15A 3 Fuse 5A 10 Battery 12V 12Ah 4 Stop buttons 11 Electronic ignition device 5 Start up button 12 Voltage regulator 6 Starter motor 13 Magneto flywheel 7 Starting relay 14 Pick up ...

Page 94: ...tch 8 Key switch contacts 3 Dipped beam upper bulb 12V 55 60W 9 Automatic starter 4 Upper beam indicator 12V 1 2W 10 Fuse 15A 5 No 3 bulbs for instrument lighting side taillights indicator 12V 2W 11 Battery 12V 12Ah 6 No 3 number plate position bulbs 12V 5W 12 Electronic ignition device ...

Page 95: ...n order not to affect the battery charge When the ignition switch is turned to the ON position the deterring blinker function is deactivated Subsequently a flash confirms the switching to the ON status This duration of the flash depends on the programming of the electronic control unit prog see figure above If the LED is off and stays off even when the ignition switch is turned to ON check if Batt...

Page 96: ...h the ignition switch turned to the ON position and the emergency cut off switch set to RUN see figure If no faults are found replace the control unit otherwise check the wiring and the following components If no malfunction is found replace the control unit and otherwise check the wiring and the following components Engine stop relay switch Emergency cut off switch Ignition switch contacts Bi Whi...

Page 97: ...2 seconds Note The time needed to change keys must not exceed 10 seconds Note A maximum of three SERVICE keys can be programmed within the same coding session It is essential to observe the sequence and time limits as described above If at any time during the programming session these are not observed the procedure will have to be restarted from the beginning Once the control unit has been coded a...

Page 98: ...aerial in working conditions and transponder code unknown Ignition disabled Vehicle immobilized 1 LED on 2 LED off 3 LED remains lit 9 2 4 2 Flash Diagnostic Code If the 2 flash diagnostic code is displayed check if the malfunction persists when the key including the MASTER key is changed If the anomaly persists with any key detach the control unit aerial connector and check the continuity of the ...

Page 99: ...y programmed and aerial in working order Ignition enabled standard operating conditions 1 LED on 2 LED off 3 No flashing 4 LED remains off 9 2 6 Ignition System Once the immobilizer system has been enabled it is possible to obtain a spark at the plug through the H T coil and the signals coming from the pick up The basic power supply is represented by the battery The system is calibrated in such a ...

Page 100: ...rogram the control unit H T coil primary circuit check Detach the control unit connector and check continuity between terminals no 3 and no 8 see figure Standard resistance H T coil secondary circuit 0 4 0 5O If the resistance is not as specified repeat the check directly on the positive and negative terminals of the H T coil primary circuit If the measured resistance is as specified proceed by re...

Page 101: ...rth and the negative terminal to the coil positive connector Standard voltage H T coil 100V If the voltage is not as specified replace the control unit Note The positive terminal of the H T coil primary circuit is black while the negative terminal is green Vi Purple Ne Black 9 2 8 Battery Charging System The battery recharge system consists of a three phase generator and a permanent magnet flywhee...

Page 102: ...If the voltage is less than 14 V check the stator and its wiring 9 2 10 Stator check Disconnect the voltage regulator connector and check for continuity between each one of the three yellow wires and the other two Standard resistance Stator 0 7 0 9O Also check that each yellow wire is insulated from earth If any of the measured values are not as specified repeat the check directly on the stator If...

Page 103: ...ormation on how to carry out the functional and resistive check of the component refer the engine section of this manual Regarding the automatic choke device power supply keep the system connector attached and check that battery voltage is present between the two terminals while the engine is running see figure If there is no voltage connect the multimeter negative terminal to ground and the posit...

Page 104: ...ground p d must be equal to battery voltage Check that the same p d battery voltage is present between terminals no 4 and no 8 black Repeat the same check between terminals no 5 light blue and no 8 black with the ignition switch turned to the ON position and the emergency cut off switch in the RUN position Rs Ne Red Black Ne Black If no voltage is detected check the wiring the connections and the ...

Page 105: ...age than prescribed The following table shows the positions and specifications of the fuses installed on the vehicle Fuse no Amperage Protected circuits 1 5A Taillight bulb number plate bulb instrument lighting and instrument light indicator 2 5A Brake light bulb starting relay switch inhibitor 3 7 5A Radio intercom pre wiring antitheft alarm pre wiring cooling liquid temperature indicator fuel re...

Page 106: ...r beam indicator G Low oil pressure indicator H Fuel reserve indicator I Speedometer L Odometer M Left turn signal indicator N Immobilizer LED A connector 1 Fuel level indicator signal 2 Upper beam indicator 3 Oil indicator 4 Power supply 5 Reserve light 6 Lighting B connector 1 Ground 2 LH turn signal indicator 3 RH turn signal indicator 4 Temperature signal ...

Page 107: ... the above operations install the battery on the vehicle following the steps described in Battery recharge section of this manual 9 2 16 2 Checking the Electrolyte Level The electrolyte level must be checked frequently and must reach the upper mark If the level is too low it can be restored only by using distilled water If water toppings are required too often check the vehicle electrical system a...

Page 108: ...ting the battery charge selector to the type of battery that requires recharging i e at a current equal to 1 10 of the battery normal capacity Connections to the power supply source must be implemented by connecting the corresponding poles to and to 9 2 16 5 Cleaning the Battery Keep the battery clean especially the top coat the terminals with Vaseline Warning Never use fuses having a greater capa...

Page 109: ...ure so to attach the wires to the terminals Note In order to correctly connect the wires to the battery terminals pay attention when placing the battery onto the tray and ensure that there are no interferences between the wires and the frame due to a possible misplacement of the battery since these might seriously affect the wiring integrity see sketch ...

Page 110: ...acing the supplied beveled washer between the screw head and the wire terminal Note Do not use a wrench to tighten the screws Once the wires are securely fastened proceed by correctly placing the battery onto the tray Replace the battery fixing clamp Replace the battery cover ...

Page 111: ...be performed with the engine cold Disconnect the battery Remove the helmet compartment Remove the side fairings Disassemble the silencer Release the three screws fixing the air filter to the crankcase Remove the clip from the blow by pipe Disconnect the carburetor bellows Then remove the air filter ...

Page 112: ... releasing the two screws shown in the figure and removing the plastic clip Remove the cooling fluid inlet piping from the pump as shown in the figure Remove the fuel tap vac uum pipe from the T union shown in the figure Remove the fuel feeding pipe from the carburetor ...

Page 113: ...he engine Also remove the bleeding piping shown in the figure Remove the spark plug cap Remove the cooling fluid temperature sensor connector shown in the figure Remove the gas control cable from the carburetor by releasing the nut shown in the figure ...

Page 114: ...located inside the protective sheath shown in the figure Remove the positive and negative wirings from the starter motor as shown in the figure Remove the flywheel wiring connector shown in the figure Remove the cable from the flywheel cover retain clip ...

Page 115: ...per by loosening the screw shown in the figure Then remove the pipe attachments to the engine crankcase shown in the figure Suitably support the vehicle by the jack Remove the engine swing arm assembly by loosening the nut and the pin head shown in the figure The engine can now be removed ...

Page 116: ...s for removal in the reverse order according to the tightening torques indicated in Chapter Characteristics Warning Be very careful in ensuring that the throttle cable is in the proper position Check that with valve in abutment against the register there is a small clearance Check the engine oil level and top up using the recommended brand if required Fill the cooling circuit Check that accelerato...

Page 117: ... engine Remove the ignition spark plug Fit a compression test gauge into the spark plug seat using a 10mm spark plug joint and tighten to the prescribed torque Let the engine run by the starter and with the carburetor in fully open position as long as the gauge value is steady If pressure is higher than 9 bar remove the tool and proceed in the reverse order of removal If the pressure is below the ...

Page 118: ... remove the driven pulley axle locking nut and washer Specific equipment and tools Driven pulley locking wrench 020423Y Remove engine oil dipstick Remove the 10 screws from the transmission cover Remove the transmission cover Note If this operation is performed without dismantling the engine from the vehicle it is necessary to remove the transmission cooling air sleeve first 10 7 2 Removing the Fa...

Page 119: ...d below Specific equipment and tools Handle 020376Y Adapter 28 30mm 020375Y 15mm Guide 020412Y 10 7 5 Fitting the Driven Pulley Shaft Bearing Heat the inside of the transmission cover in order to prevent the paint on the outer surface Install the bearing onto its seat Replace the snap ring Specific equipment and tools Handle 020376Y Adapter 32 35mm 020357Y 15mm Guide 020412Y Warning Ensure to use ...

Page 120: ...ls Handle 020376Y 25mm Guide 020364Y 10 7 7 Refitting the Belt Support Roller Heat the roller and install the bearing using the following tools Specific equipment and tools Heat gun 020151Y Heat gun support 020364Y Handle 020376Y Adapter 32 35mm 020357Y 10mm Guide 020455Y Reposition the roller using the specific screw Tighten at the prescribed torque Tightening torque Anti flapping roller 8 1 9 6 ...

Page 121: ...with the O ring and the steel washer on the bushing Remove the belt and extract the moving half pulley with the relevant bushing Note The rollers are freely placed onto the slides inside the pulley Ensure that they don t fall when the pulley is being removed Remove the roller contrast plate with the relevant guide sliding blocks 10 7 9 Removing the Driven Pulley Remove the spacer the clutch drum a...

Page 122: ...m 10 7 11 Checking the Clutch Drum Surface Eccentricity Install the drum on a driven pulley shaft using two bearings internal diameter 15 and 17mm Use the original spacer nut to lock the drum shaft assembly Place the drum shaft assembly on the support 020074Y to check the driving shaft alignment Using a feeler pin comparator and the magnetic base measure the drum eccentricity Repeat the measuremen...

Page 123: ...remove the clutch fixing nut Separate the components of the driven pulley clutch and spring with plastic rest Specific equipment and tools Driven pulley spring compressor 020444Y Wrench 46 55mm 020444Y009 Adapter ring 020444Y011 Caution The toll must be tightly fixed in the vice and the central screw must be moved in abutment with the tool An excessive torque may deform the specific tool 10 7 13 D...

Page 124: ...3Y Bell no 35 001467Y035 10 7 14 Checking the Fixed Driven Half Pulley Measure the external diameter of the bushing see figure Standard dimension Bushing diameter 1 598 in 40 985mm Min allowable dimension Bushing diameter 1 597 in 40 960mm Ensure that the working surface in contact with the belt is free from abnormal wear Check the riveting Check the planarity of the working surface Wear limit Fix...

Page 125: ...e that the working surface in contact with the belt is free from abnormal wear Check the riveting Check the planarity of the working surface Wear limit Fixed Driven pulley planarity 0 0012 in 0 03mm 10 7 16 Fitting the Fixed Driven Half Pulley Bearings Ensure the pulley bushing is suitably supported from the threaded side on a wooden surface Install the new roller casing as shown in the figure ens...

Page 126: ... assembly ensure the working surface is in good conditions and shows no signs of abnormal or wear as described in the previous section Insert the new oil seals and O rings on the moving half pulley Carefully grease the O ring marked as A in the figure Install the half pulley on the bushing using the specific tool Specific equipment and tools Protective sheath 020263Y Ensure that the pins and the c...

Page 127: ...nstalled or during their replacement It may be easier to proceed with the lubrication during overhaul 10 7 18 Checking the Moving Driven Half Pulley Spring Measure the length of the moving driven half pulley spring as shown in the figure Note The spring must be unloaded Standard dimension Spring length 4 84 in 123mm Min allowable dimension Spring length 4 65 in 118mm 10 7 19 Checking the Drive Bel...

Page 128: ...es of lubricant If they do check the seal of the driven pulley assembly Note Upon the running in period the clutch shoes must have a central contact surface and must not differ from one another otherwise the clutch may slip Warning Do not use a tool to open the shoes as this may affect the return spring load 10 7 21 Fitting the Clutch Place the driven pulley onto the compressor tool as shown in th...

Page 129: ...0 7 22 Checking the Moving Driving Half Pulley Check that the bearing shown in the figure is not worn and measure the internal diameter Standard dimension Internal bearing diameter 1 0140 1 0148 in 26 000 26 021 mm Max allowable dimension Internal bearing diameter 1 0283 in 26 12 mm Warning Do not lubricate or clean the bushes Measure the pulley sliding bushing external diameter shown in the figur...

Page 130: ...he fixed driving pulley exhibits no abnormal wear on the grooved profile and on the belt contact surface Check that the O Ring is not deformed 10 7 23 Fitting the Fixed Driving Half Pulley and Bushing Assembly Pre assemble the mobile half pulley with the roller contrast plate placing the rollers in the specific slits with the larger matching surface in contact with the pulley according to the dire...

Page 131: ... start up rim assembly with torque limiter Prevent the half pulley rotation using the specific lock wrench Insert the torque limiter on the driving shaft so as to ensure the alignment of the references obtained on the start up rim and on the fixed driving half pulley If this is not possible choose the position where the references are closest to one another Failure to comply with this rule can imp...

Page 132: ...ment and tools Lock wrench 020368Y The torque limiter is calibrated at 71 7 lbs ft 100 N m The lock wrench works on the starting rim If the torque limiter is worn it is possible to detect the fault when locking of the nut on the driving shaft The torque limiter cannot be overhauled In case of anomalies replace the start up rim with the limiter 10 7 25 Fitting the Clutch Drum Fit the clutch drum an...

Page 133: ...ite Super Rapid 242E thread locking compound to the threads and tighten the driven pulley shaft nut to the specified tightening torque using the lock wrench specific tool Re fit the plastic cover Specific equipment and tools Lock wrench 020423Y Tightening torques Transmission cover screws 8 1 9 6 lbs ft 11 13 N m Driven pulley axis 39 8 44 2 lbs ft 54 60 N m 10 7 27 Removing the Rear Hub Cover Rem...

Page 134: ...he Hub Casing Bearings Check the condition of the hub casing bearings wear play noise If any anomalies are found proceed as described below Remove the three 0 585 in 15mm bearings two on the crankcase and one on the hub cover using the specific extractor Specific equipment and tools 0 585 in 15mm Pliers 001467Y013 Bell 001467Y009 ...

Page 135: ...b cover as shown in the figure Remove the bearings using the specific tools Specific equipment and tools Column kit 020489Y Handle 020376Y 1 46 in 37mm adapter 020477Y 1 18 in 30mm guide 020483Y Using the specific tools remove the oil seal as shown in the figure Specific equipment and tools Handle 020376Y 42 47mm adapter 020359Y ...

Page 136: ... ring shown in the figure Using the modular punch remove the driven pulley shaft bearing Specific equipment and tools Handle 020376Y 1 10 1 18 in 28 30mm adapter 020375Y 0 78 in 20mm guide 020363Y 10 7 32 Checking the Hub Cover Ensure that the mating surface is not dented or distorted Check that the bearing housing shows no signs of wear or cracks If any defects are found replace the hub cover 10 ...

Page 137: ...tric ball containment type place it as shown in the figure Specific equipment and tools Handle 020376Y 42 47mm adapter 020359Y 0 787 in 20mm guide 020363Y Replace the Snap ring Note To install the bearings onto the engine crankcase it is necessary to ensure that the crankcase is supported in such a way to allow the bearings to be placed vertically 10 7 34 Fitting the Wheel Axle Bearing on the Cove...

Page 138: ...t Specific equipment and tools Handle 020376Y 2 047 2 165 in 52 55mm adapter 020360Y Note The 2 047 in 52mm side of adapter 020360Y must face the bearing 10 7 35 Checking the Hub Shafts Ensure that the three shafts exhibit no signs of wear or deformation especially at the toothed surfaces and at the bearing and oil seal housings Replace any damaged parts ...

Page 139: ...e vent pipe gasket using black silicone sealant Install the cover ensuring that the breather pipe is correctly positioned Place the three shorter screws which are different in color and the pipe support plate in as shown in the figure Position the remaining four screws and then tighten all the seven screws with the prescribed torque Tightening torques Hub cover screws 17 6 19 9 lbs ft 24 27 N m ...

Page 140: ...emove the two clamps and sleeves shown in the figure and then drain the cooling system Remove the two clamps fixing the SAS valve connection sleeve to the drainage pipe Remove the two fastening screws the secondary air connection pipe and the relevant copper gasket ...

Page 141: ... by releasing the four hexagonal head screws shown in the figure Remove the two screws fixing the SAS valve to the flywheel cover Remove the SAS valve complete with the gasket Remove the three screws fixing the SAS valve support to the flywheel cover as shown in the figure ...

Page 142: ...AS valve support complete with its gasket Remove the external filter shown in the figure Remove the flywheel cover with the two centering dowels as shown in the figure Remove the inside filter cover shown in the figure ...

Page 143: ...dary air box valve and flywheel cover may cause an increase of noise Check that the sleeve connecting the secondary air to the head exhibits no cracks or deformations Replace them if necessary Check that the metal duct is free from cracks 10 8 2 Removing the Flywheel Using the adjustable spanner hold the flywheel in position see figure Specific tools and equipment Adjustable wrench 020565Y Loosen ...

Page 144: ...move the two pick up screws indicated by two black arrows in the figure the wiring clip screw and the two stator fixing screws white arrows Remove the stator and the related wiring 10 8 4 Checking the Stator Using a multimeter check for continuity between connections 5 3 and 5 1 Check ground insulation on the three stator phases 5 ground 3 ground 1 ground Standard resistance For each phase 0 5 1 0...

Page 145: ...perature Checks carried out with the stator at operating temperature give higher resistances than the rated values 10 8 7 Checking the Flywheel Check the integrity of the internal plastic parts of the flywheel and the Pick Up control plate 10 8 8 Fitting the Stator Assembly Fit the stator and the flywheel by following the removing procedure in the reverse order Tighten the fastenings with the pres...

Page 146: ...ick up clearance gap ranges between 0 013 0 029 in 0 34 0 76mm No adjustment of the clearance gap is necessary when fitting the pick up Different values are the result of deformations of the pick up support Note A variation of the clearance gap changes the minimum supply speed if the ignition system 10 8 10 Fitting the Flywheel Cover Assembly Position the flywheel so that the TDC reference mark is...

Page 147: ... bolts Replace the plastic support for the secondary air box valve and tighten wit the prescribed torque Tightening torques Flywheel fixing nut 2 2 2 9 lbs ft 3 4 N m Replace the secondary air box valve with its gasket and tighten with the prescribed torque Tightening torques Secondary air box valve screw 2 2 0 4 lbs ft 3 0 5 N m Replace the rubber sleeve and the metal pipe connecting the SAS valv...

Page 148: ... as shown in the figure Set the pump onto vacuum mode Open the pump slowly Check that the one way valve allows the passage of air this should generate a small vibration Note The absence of vibration indicates a poor sealing Switch the pump onto pressure mode Open the pump and check that there is an increase in pressure Small leaks are normal Note The incorrect operation of the one way valve can ca...

Page 149: ...nt Note Besides impairing the functionality of the cut off an incorrect seal of the cut off valve membrane affects the engine operation at idle Using a T branch and rubber hoses implement a parallel connection between the rubber sleeve and the vacuum inlet of the cut off valve Connect the branch to the mityvac pump as shown in the figure Set the pump in vacuum position Using pliers with flat tips ...

Page 150: ...vacuum suddenly resets A seal failure or an opening at inconsistent pressure values is not to be considered as acceptable Replace the component Note A seal failure of the cut off valve causes exhaust noises explosions in the silencer A wrong calibration of the cut off valve can impair the correct functionality of the catalytic converter Specific tools and equipment Mityvac pump 020329Y ...

Page 151: ...151 10 10 Lubrication Circuit ...

Page 152: ...t a temperature of 194 F 90 C check that the oil pressure is in the range 3 2 4 2 atm After completing the check remove the specific tools fitted to the engine refit the low oil pressure switch with its washer and tighten it with the prescribed torque Then fit the flywheel cover If abnormal pressures are found check in the following order the oil filter the by pass the oil pump and the crankshaft ...

Page 153: ...own in the figure with the two rear brake fluid pipe clamps Remove the spring the by pass piston the gasket and the centering dowels shown in the figure 10 10 3 Checking the By Pass Valve Check the unloaded length of the spring Standard dimension By pass valve spring length 2 11 in 54 2 mm Check that the piston exhibits no signs of superficial defects Ensure that it slides freely on the crankcase ...

Page 154: ...the supplied screws Specific equipment and tools Transmission side oil seal punch 020662Y Screw the threaded bar at the base of the tool and remove the oil seal Remove the pump control rim cover by loosening the two screws shown in the figure Hold the oil pump control pulley in place and thus preventing it from rotating by inserting a screwdriver through one of the holes ...

Page 155: ...0 10 5 Checking the Oil Pump Remove the two screws and the oil pump cover Remove the inner rotor circlip Remove the rotors and carefully clean them with gasoline and compressed air Reassemble the rotor with the pump body leaving the reference marks visible Re fit the snap ring Using a thickness gauge check the distance between the rotors in the position shown in the figure Max allowable clearance ...

Page 156: ...lignment of the holes for the screws fastening the pump to the crankcase Tighten the fastening screws with specified torque Tightening torques Oil pump crankcase fixing screws 0 51 0 66 lbs ft 0 7 0 9 N m Ensure that the gasket is correctly positioned and then fit the pump to the crankcase The pump can only be fitted in one position Tighten the screws with the prescribed torque Tightening torques ...

Page 157: ...ghtening shoe is not worn If so replace it or fit it the other way round to make it work on the other side Using the specific tools listed below remove the oil seal Specific tools and equipment Handle 020376Y 32 35mm adapter 020357Y Prepare the new oil seal carefully lubricating the sealing lip Warning Do not lubricate the surface keyed onto the engine crankcase Pre assemble the oil seal with the ...

Page 158: ...el facing downwards When the seal is in place do not pull it back outwards Failure to comply with this rule can cause a wrong positioning of the oil seal sheath Finally place the oil seal installing the bracket from the specific tool kit Screw the threaded bar onto the crankshaft Using the nut at the base of the tool position the oil seal at its position Carefully remove all the tooling ...

Page 159: ... spring into the projection in the sump Fit the screws and the rear brake pipe clamps by following the removing procedure in the reverse order Tighten the screws with the prescribed torque Tightening torques Oil sump screws 7 4 10 3 lbs ft 10 14 N m Fit the driving pulley assembly the belt the pinion and the transmission cover as described in the chapter Transmission Regarding the checks relating ...

Page 160: ...mponents transmission cover driving pulley and belt starter Bendix oil sump with spring and blow by piston lower oil pump sprocket cover O ring on crankshaft and oil pump sprockets timing chain disk Remove the rocker cover Remove the central screw fastener and the automatic valve lifter retaining cover Remove the automatic valve lifter cam together with its end stop ring Loosen the central screw o...

Page 161: ...stener indicated by the arrow in the figure the stator and the chain guide Note Mark the chain in order to replace it with the same direction of rotation The chain tensioning pad must be removed from the transmission side The chain guide can only be removed following the removal of the cylinder head 10 10 12 Removing the Camshaft and Rockers Remove the two screw fasteners and the camshaft retainer...

Page 162: ...g Remove the two screw fasteners on the outside of the cylinder head shown in the figure Loosen the four cylinder head securing nuts in two or three stages following a diagonal crosswise sequence Remove the cylinder head the two locating dowels and the cylinder head gasket Note If necessary the cylinder head can be removed as a complete assembly together with camshaft rocker pin and camshaft suppo...

Page 163: ...l 020382Y Adapter 020382 11Y Warning Place the valves so as to recognize their original position on the head Remove the valve seals with the appropriate special tool Special tools and equipment Oil seals removing tool 020431Y Remove the spring seats 10 10 15 Removing the Cylinder and Piston Assembly Remove the chain guide Remove the cylinder base gasket Warning Ensure the piston is well supported ...

Page 164: ...the Small End Measure the internal diameter of the small end using an internal micrometer Standard dimension Small end diameter 0 5911 0 5915 in 15 015 15 025 mm Max allowable dimension Small end diameter 0 5917 in 15 030 mm Note Whenever the small end exceeds the wear limit or shows signs of wear or overheating replace the crankshaft with a new one as described in the following pages ...

Page 165: ... channels so in order to get a true reading of the internal diameter the measurement must be taken parallel to the axis of the piston 10 10 18 Inspecting the Piston and Cylinder Diameters Measure the outside diameter of the piston perpendicular to the wrist pin axis Take this measurement 0 197 in 5 mm from the base of the piston as shown in the figure Standard diameter Piston diameter 2 8328 2 833...

Page 166: ...ce roughness of the bored surface of the cylinder should be 0 00004 in 0 9 m This is imperative to ensure proper bedding in of the piston rings and hence reduced oil consumption and optimum performance 1st 2nd and 3rd over size pistons are available as spare parts for re bored cylinders corresponding to 0 2 0 4 and 0 6 mm over sizes respectively There are four categories for matching oversize cyli...

Page 167: ... axis of the cylinder Measure the piston ring gap using feeler gauges Replace piston rings exhibiting a gap exceeding the specified limit Note Before replacing the piston rings alone on the original piston check the piston ring to groove clearance and the piston to cylinder clearances are within the specified limits The new rings may sit differently that the old ones which had bedded in when fitte...

Page 168: ...e tool and push home to the circlip into the correct position on the hollow tool Insert the shorter of the two drifts into the hollow part of the tool offer up the couple to the circlip groove and push the shorter drift home to push the circlip into its groove on the piston Warning Using a mallet to fit the circlip can damage the circlip grooves 10 10 22 Choosing the Base Gasket Thickness Fit the ...

Page 169: ...amage the circlip grooves With fiber gasket thickness 0 0433 in 1 1 mm Measured recess Gasket thickness 0 0197 0 0236 in 0 5 0 6 mm 0 0157 0 0020 in 0 4 0 05 mm 0 0236 0 0315 in 0 6 0 8 mm 0 0236 0 0020 in 0 6 0 05 mm 0 0315 0 0354 in 0 8 0 9 mm 0 0315 0 0020 in 0 8 0 05 mm With metal gasket thickness 0 0118 in 0 3 mm Measured recess Gasket thickness 0 0118 0 0078 in 0 3 0 2 mm 0 0157 0 0020 in 0 ...

Page 170: ... The top piston ring with the word TOP or the reference mark facing the crown of the piston Note In order to improve the b edding in of the rings the surfaces on the top two piston rings are angled to give a conical section of contact Note Offset the piston ring gaps on the three rings by 120 to each other and lubricate the components with engine oil 10 10 24 Fitting the Cylinder Fit the base gask...

Page 171: ...d the rocker pin for signs of wear Inspect the flat surfaces on the cylinder head cover the inlet manifold and the exhaust manifold Hole Standard diameter A 0 4724 0 4731 in 12 000 12 018 mm B 0 7874 0 7882 in 20 000 20 021 mm C 1 4567 1 4577 in 37 000 37 025 mm 10 10 26 Checking the Valve Seals Measure the width of the sealing surfaces on the valve heads Standard dimension Valve sealing width int...

Page 172: ...eat diameter exhaust 0 1969 0 1973 in 5 000 5 012 mm Max allowable dimension Valve seat diameter intake 0 1977 in 5 022 mm Max allowable dimension Valve seat diameter exhaust 0 1977 in 5 022 mm Check the width of the wear on the valve seat indicate by V in the figure does not exceed a width of 0 063 in 1 6 mm If the wear exceeds this limit replace the cylinder head with a new one 10 10 28 Inspecti...

Page 173: ...4 in 94 6 mm Standard dimension Valve length exhaust 3 717 in 94 4 mm If any of the sealing surface of the valve does not conform to the specified wear limits or is damaged or curved replace the valve with a new one 1 YES 2 NO It is advisable to grind the valve seats which should be done using a fine grade grinding paste During the grinding operation hold the cylinder in such a position as to keep...

Page 174: ...hut with just the force of a finger 10 10 30 Checking the Valve Spring Plates and Half cones Check that the spring upper support plates and half cones are free from irregular wear 10 10 31 Fitting the Valves Lubricate the valve guides with engine oil Place the valve spring seats on the cylinder head Using the special drift fit the four valve seals Specific tools and equipment Oil seals installing ...

Page 175: ...t the chain guide and the chain tensioner for signs of excessive wear Check there is not excessive wear on the timing chain the camshaft sprocket and the timing chain sprocket on the crankshaft Replace worn components as necessary and in the case of wear on the timing chain or sprockets replace all three components as a group Remove the chain tensioning screw with the associated washer and spring ...

Page 176: ...n Cam height intake 1 1923in 30 285 mm Standard dimension Cam height exhaust 1 1500 in 29 209 mm Check there is no wear on the camshaft retaining plate and its associated groove on the camshaft Max allowable clearance Camshaft retaining plate 0 020 in 0 42 mm If any of the above dimensions are outside the specified limits or there are signs of excessive wear replace the defective components with n...

Page 177: ...take up the axial play between the rockers Replace any defective components with the new ones 10 10 34 Fitting the Cylinder Head Fit the timing chain guide Insert the centering dowels between head and cylinder Install the head gasket and then place the head onto the cylinder Lubricate the stud threading Fit the cylinder head nut fasteners and tighten them in a crosswise sequence in two or three st...

Page 178: ...Loop the timing chain around the sprocket on the crankshaft Fit the chain tensioner guide to the cylinder head Fit the spacer and the fastening screw and tighten the screw at the prescribed torque Tightening torque Tensioner screw 7 4 10 3 lbs ft 10 14 N m Fit the rocker pin the exhaust rocker the spring washer and the inlet washer Lubricate the rockers via the holes on top Lubricate the cam surfa...

Page 179: ...atic valve lifter cam to the camshaft Note Lubricate the end stop ring with grease in order to avoid it from coming loose accidentally and falling inside the engine Fit the automatic valve lifter return spring pre loading it by a 180 rotation Fit the automatic valve lifter retaining dish using the counterweight fastening screw as a reference Tighten the screw to the specified tightening torque Tig...

Page 180: ...ojections on the timing chain side provide a reference for its orientation Fit the head cover and tighten the five screws at the prescribed torque Check the proper position of the gasket Tightening torque Rocker cover screw 4 4 5 1 lbs ft 6 7 N m Fit the flywheel cover as already described in the Flywheel chapter Fit the oil pump drive the oil pump cover the oil blow by valve and the sump see Lubr...

Page 181: ...asket is properly positioned Install the thermostat cover with the carburetor heating connection facing the flywheel Tighten the two screws at the prescribed torque Tightening torque Thermostat screw 2 1 2 8 lbs ft 3 4 N m 10 10 37 Fitting the Intake Manifold Install the intake manifold and tighten the three fastening screws ...

Page 182: ... water pump flywheel and stator Flywheel chapter Remove the oil filter and the oil low pressure sender Remove the cylinder head and cylinder piston assembly see the previous chapter Remove the two screws shown in the figure and the starter motor Before separating the crankcase halves it is worthwhile to measure the end float on the crankshaft Use a dial gauge and support attached to the crankcase ...

Page 183: ...During separation of the crankcase halves and removal of the crankshaft take care that the threaded ends of the crankshaft do not damage the main bearings Note The crankshaft is installed with two steel shim adjusting washers Make a note of the fitting position Recommended tools and equipment Crankcase detachment plate 020262Y Dial gauge with magnetic base 020335Y Standard clearance Crankcase 0 00...

Page 184: ...the crankshaft as the curvature in the corner may cause inaccurate readings Standard dimension with shim adjusting washers 2 024 2 026 in 51 40 51 45 mm Standard dimension 2 192 2 199 in with integral washers 55 67 55 85 mm Warning The crankshaft can be re used as long as its width is within the specified limits and shows no signs of scoring If present check that the shim adjusting washers show no...

Page 185: ...kshaft aligning tool 020074Y Crankcase Crankshaft Half crankshaft bearings Class 1 Class 2 Crankcase 1 2973 1 2978 32 953 32 963 A type Red B type Blue C type Yellow Half crankshaft bearing 0 0776 0 0777 1 970 1 973 0 0777 0 0778 1 973 1 976 0 0778 0 779 1 976 1 979 Half crankcase Half crankshaft Bearing Cat 1 Cat 1 B Cat 2 Cat 2 B Cat 1 Cat 2 A Note Spare crankcases are selected with half crankca...

Page 186: ...se half take particular care in cleaning the oil ducts for the main bearings the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the flywheel side oil seal Note The oil duct for lubrication of the cylinder head is fitted with a vaporizer jet that provides so called low pressure lubrication designed to keep the oil temperature in the sump at an acceptable level B...

Page 187: ...l the plane of the coupling between the two half bearings must be absolutely perpendicular to the axis of the cylinder as shown in the figure The depth to which the half bearings are driven in relation to the surface that limits the axial play of the crankshaft can also affect the alignment of the oil ducts Standard dimension Main bearing bedding in depth 0 053 0 063 in 1 35 1 60 mm Note The main ...

Page 188: ...n Crankcase bearing housing 32 953 32 963 mm Main half bearings are divided into three categories according to their thickness see table in the previous page for details Bearing category Half crankcase category Bearing internal diameter as assembled Mating option A 1 1 1427 1 1433 in 29 025 29 040 mm Original 1 1 1425 1 1431 in 29 025 29 040 mm B 2 1 1428 1 1434 in 29 028 29 043 mm Original and sp...

Page 189: ...their original position Fit the eleven screws and tighten them to the prescribed torque Tightening torque Half crankcase coupling screws 8 1 9 6 lbs ft 11 13 N m Note Remove any remains of the old gasket from the crankcase and cylinder mating surfaces in order to ensure proper seals Lubricate the flywheel side oil seal Using the appropriate special tool fit the oil seal Recommended tools and equip...

Page 190: ...nd lubricate it Fit the starter motor to the crankcase and tighten the two screw fasteners to the specified tightening torque Tightening torque Half crankcase coupling screws 8 1 9 6 lbs ft 11 13 N m Note Re fit the remaining engine components as described in the previous pages ...

Page 191: ...the pipe supplying air to the membrane and the inlet connection Pull off the carburetor and rotate it to remove the screw with the water connection complete with pipes Note This operation is necessary to avoid emptying the cooling system It is also necessary to disconnect the cut off vacuum supply pipe Remove the protection the clamp and the automatic choke device after loosening the two screws sh...

Page 192: ... and the cap with the membrane chamber filter Remove the four fixing screws shown in the figure and the vacuum chamber cover Caution The spring can suddenly jump out during the operation of removal Take care to contain it ...

Page 193: ...193 Remove the vacuum valve with the membrane Turn the coupling by turn and remove it Remove the spring and the vacuum valve pin Remove the four screws shown in the figure ...

Page 194: ... outlet valves from the bowl Note Pay particular attention when handling the valves since they consist of nozzles springs and metallic spheres Note Do not remove the accelerator pump piston and control Using a hammer and with the carburetor suitably supported remove the float pin from the throttle valve side Remove the float ...

Page 195: ...195 Remove the main jet Loosen the emulsion jet Tilt the carburetor and remove the emulsion jet ...

Page 196: ...dling jet Remove the idle speed flow screw and spring Warning Do not attempt to remove components pressed into the carburetor body These include the fuel feed duct the needle valve seat the starter jet the emulsion tube plug the accelerator jet the air adjuster minimum and maximum the butterfly valve and the butterfly valve control arm The screw fasteners have been crimped after fitting and removi...

Page 197: ...ipe supplying air to the membrane and the inlet connection Pull off the carburetor and rotate it to remove the screw with the water connection complete with pipes Note This operation is necessary to avoid emptying the cooling system It is also necessary to disconnect the cut off vacuum supply pipe Remove the protection the clamp and the automatic choke device after releasing the screw shown in the...

Page 198: ... the four fixing screws shown in the figure and the vacuum chamber cover Caution The spring can suddenly jump out during the operation of removal Take care to contain it Remove the vacuum valve with the membrane ...

Page 199: ...199 Turn the coupling by turn and remove it Remove the spring and the vacuum valve pin Remove the four screws shown in the figure ...

Page 200: ...Remove the sealing gasket Remove the accelerator pump inlet and outlet valves from the bowl Note Pay particular attention when handling the valves since they consist of nozzles springs and metallic spheres Note Do not remove the accelerator pump piston and control ...

Page 201: ...g a hammer and with the carburetor suitably supported remove the float pin from the throttle valve side Remove the float Remove the cap conveying fuel to the starting jet shown in the figure Remove the main jet ...

Page 202: ...Remove the atomizer Note This operation is necessary to avoid loosing the atomizer while cleaning the carburetor body If the atomizer is jammed in its housing do not attempt to remove it or it may get damaged Remove the idling jet ...

Page 203: ...not attempt to remove components pressed into the carburetor body These include the fuel feed duct the needle valve seat the starter jet the emulsion tube plug the accelerator jet the air adjuster minimum and maximum the butterfly valve and the butterfly valve control arm The screw fasteners have been crimped after fitting and removing them will damage the arm ...

Page 204: ...ow running circuit concentrating in the following points the air screw the passage within the slow running screw mechanism and the auxiliary channel openings around the butterfly valve For the starter circuit concentrate on the jet duct as the housing blocks the calibrated holes making them inaccessible Thoroughly blow out the accelerator pump jet Note The jet outlet is extremely small and directe...

Page 205: ...xcessive wear If any of the above defects are observed replace the carburetor with a new one Note Do not insert metal tools or instruments into the calibrated jets as these can cause damage and alter the carburetion Thoroughly clean and blow the slow running jet and re fit it Thoroughly clean and blow the main supply circuit components the atomizer the emulsion jet and the main jet Insert the atom...

Page 206: ... infiltrated the float If there are any defects replace the float with a new one Re fit the float together with the needle inserting the pin from the fuel inlet side Note Ensure the return spring on the float tab is in the correct position 10 11 9 2 Walbro WFV 7P Carburetor Before reassembling the carburetor carefully clean the carburetor body using fuel and compressed air Take particular care in ...

Page 207: ...s directed otherwise Check that on the carburetor there are five ball bearing seals pressed into the holes machined in the carburetor body Check that the two mating surfaces between the float bowl and the diaphragm are unblemished Check the butterfly valve and control arm Check that the float valve housing channel shows no signs of scoring Check that the valve seat shows no signs of abnormal or ex...

Page 208: ... with the needle inserting the pin from the fuel inlet side Note Ensure the return spring on the float tab is in the correct position 10 11 10 Checking the Float Height 10 11 10 1 Kehin CVK 30 Carburetor Holding the carburetor upside down check that the float is parallel to the plane of the bowl If found to be out of alignment adjust by bending the metal tab that controls the needle until correcte...

Page 209: ...o the specified torque Check that the throttle rocker arm rotates freely onto its seat Note Check that the gasket is inserted properly Note Avoid excessively loading the accelerator pump rocker arm control Clean and blow the idle speed flow screw Check that the screw is free from oxidation and or deformations Fit the spring onto the screw as shown in the picture Tighten the flow screw onto the car...

Page 210: ...and or pin as necessary Thoroughly clean and blow the fuel conveying cap and insert it onto the starter jet Note Failure to install this component results in worse cold starting performance since the starter jet draws old fuel from the bottom of the bowl Remove the float bowl drainage screw and then thoroughly clean and blow out the bowl paying particular attention in cleaning the accelerator pump...

Page 211: ... accelerator pump rocker arm control Clean and blow the idle speed flow screw Check that the screw is free from oxidation and or deformations Fit the spring onto the screw as shown in the picture Tighten the flow screw onto the carburetor body and adjust its final position by carrying out an exhaust gas analysis Prepare the carburetor for a djustment with the screw loosened by two turns from its c...

Page 212: ...e Needle 10 11 11 1 Kehin CVK 30 Carburetor Ensure the vacuum valve float pin is free from wear Check that the vacuum valve exhibits no scratched on the surface Ensure that the vacuum feeding hole is not clogged Check that the membrane is not broken or hardened if not so replace the entire valve Insert the float pin into the vacuum valve seat Replace the vacuum throttle valve on the carburetor pay...

Page 213: ...th the pin lock After ensuring that the spring is properly positioned into the housing fit the vacuum chamber cover Clean and blow the ambient pressure inlet filter sponge Fit the filter and its clamp as shown in the figure ...

Page 214: ...h Check that the vacuum valve exhibits no scratched on the surface Ensure that the two vacuum feeding holes are not clogged Note The two holes have different diameters Check that the membrane is not broken or hardened if not so replace the entire valve Insert the float pin into the vacuum valve seat Replace the vacuum throttle valve on the carburetor paying attention in inserting the pinto into th...

Page 215: ...e unloaded length of the spring Standard dimension Spring 0 945 in 24 mm Fit the membrane with the metal pin positioned on the valve Fit the spring and the cover The cover must have the vacuum inlet facing upwards 10 11 12 Checking the Automatic Choke Device 10 11 12 1 Kehin CVK 30 Carburetor Check that the piston picture exhibits no scratches or oxidation and that it slides freely into the seat C...

Page 216: ...oke and check that the piston reaches its maximum protrusion Note When performing this check do not generate any short circuits It is therefore necessary to use a cable with suitable terminals The effective heating time depends on the ambient temperature If measured projection resistance or time values are inconsistent with the prescribed ones replace the automatic choke assembly Install the choke...

Page 217: ...F 20 C 0 492 0 512 in 12 5 13 0 mm The choke should gradually disengage as it is being heated electrically Check the choke resistance at ambient temperature Standard resistance Choke resistance 68 F 20 C 40 O Using a 12V battery power the automatic choke and check that the piston reaches its maximum protrusion Note When performing this check do not generate any short circuits It is therefore neces...

Page 218: ... the carburetor checking the proper positioning of the O Ring insert the plate with the knurling resting against the choke and tighten the fixing screw Orientate the choke device as shown in the figure Install the safety casing ...

Page 219: ...219 10 12 Cooling System 10 12 1 Cooling Circuit 1 Expansion tank 4 Carburetor heating circuit 2 LH radiator with electric fan 5 Electric fan switch 3 Thermostat with by pass 6 RH radiator ...

Page 220: ... fastenings shown in the figure Position the flywheel cover on the ring shaped base that is part of tool part no 020440Y Specific tools and equipment Ring base 020440Y Note To prevent damage to the cover surface designed to ensure coolant tightness use the ring shaped base with the accurately machined surface facing the flywheel cover Using a press and the drift that is part of tool no 020440Y eje...

Page 221: ...r is perfectly horizontal Using the drift in inverted position eject the two ball bearings 10 12 3 Checking the Components Check that the impeller is not cracked or worn Check that the impeller shaft is not oxidized Check that no oxidation is present on the ceramic seal and bearing housings Ensure that the drive is not cracked and that it is perfectly joined to the steel hub ...

Page 222: ...ings on the specific tool Drive the bearing fully home into the crankcase using a plastic mallet Assemble the ceramic ring with the rubber gasket The ceramic ring bevel must face the gasket Lubricate the rubber gasket and fit the assembly to the flywheel cover If necessary use the drift from 020440Y only by hand Note Always use new ceramic rings and gaskets Failure to manually install the ceramic ...

Page 223: ...its abutting end Note Carefully center the punch onto the impeller Apply force to the shaft and check that the flywheel cover rotates horizontally Failure to observe this rule may result in damage to the drive Refit the impeller cover using a new O ring Tighten the three fixing screws at the prescribed torque Tightening torque Impeller cover fixing screws 2 2 2 9 lbs ft 3 4 N m Note Do not lubrica...

Page 224: ... container by using the hot air gun Specific tools and equipment Hot air gun 020151Y Measure the temperature at which the thermostat begins to open Standard temperature Thermostat opening 157 1 162 5 F 69 5 72 5 C Heat until the thermostat opens completely Standard dimension Thermostat opening 0 136 in travel at 176 F 80 C 3 5 mm Warning To properly conduct the test avoid direct contact between th...

Page 225: ...the operations that may be carried out on the suspensions Lubricate with oil Clean carefully Lubricate with grease Caution handle with care Apply product Always replace A B C D E F G Qty 5 2 1 1 1 1 2 Torque lbs ft N m 73 88 104 126 63 77 90 110 18 21 25 30 ...

Page 226: ... hub and tighten the five screws at the prescribed torque Tightening torque Wheel fixing screws 14 0 17 5 lbs ft 20 25 N m 11 2 Removing and Refitting the Rear Wheel Remove the silencer rear shock absorber bracket Remove the five Allen screws shown in the figure For refitting tighten the five screws at the prescribed torque and reassemble the bracket Tightening torque Wheel fixing screws 14 0 17 5...

Page 227: ...oving the Steering Column Remove the front wheel Remove the front caliper Loosen the odometer fixing plate screw to remove the cable Remove the suspension arm cover by releasing the three screws shown in the figure ...

Page 228: ... the front mudguard as shown in the figure Remove the brake tube clamp from the top plate of the shock absorber Remove the brake tube fixing from the suspension arm Pre loosen the three nuts fixing the mudguard to the front suspension bracket ...

Page 229: ...teering column ball cage bearing seat ring nut Extract the steering column and remove the mudguard from the suspension Specific tools and equipment Steering column ring nut spanner 020055Y For re assembly follow the operations for removal in the reverse order carefully applying grease on the steering column ball cage bearing seats and tightening at the prescribed torques Tightening torques Upper r...

Page 230: ...wheel axle nut cap shown in the figure Remove the wheel axle nut Extract the wheel hub complete with brake disk from its axle For re fitting perform the operations for removal in the reverse order Tightening torque Wheel axle nut 53 63 lbs ft 75 90 N m 11 5 Front Wheel Hub Overhaul Remove the snap ring shown in the figure ...

Page 231: ...move the roller bearing Specific tools and equipment Handle 020376Y Adapter 020456Y 0 787 in 20mm guide 020363Y With the aid of the hot air gun heat the roller bearing seat Using the specific tool insert the bearing with the screened side facing outwards and push it home Refit the snap ring Specific tools and equipment Handle 020376Y 1 7 1 8 in 42 47 mm adapter 020359Y 0 591 in 15 mm guide 020412Y...

Page 232: ... side Apply grease JOTA 3 FS between ball and roller bearings Specific tools and equipment Punch 020038Y 11 6 Removing the Front Brake Caliper Shock Absorber Bracket Remove the wheel hub and the brake disk Remove the front shock absorber lower fixing screw Remove the bracket lock snap ring Extract the bracket ...

Page 233: ...htening torque Shock absorber lower fixing screw 14 19 lbs ft 20 27 N m 11 7 Front Brake Caliper Shock Absorber Bracket Overhaul The caliper shock absorber fixing bracket is provided with two roller bearings spaced from one another as shown in the figure Remove the two roller bearings from the bracket using the specific tool form the shock absorber coupling side as shown in the figure Specific too...

Page 234: ... Specific tools and equipment Handle 020376Y 2 0 2 2 in 52 55 mm adapter 020360Y Using the specific tool install a new roller bearing on the shock absorber side and push it home Specific tools and equipment Punch 020036Y Suitably support the chock absorber brake caliper bracket Using the specific tool install a new roller bearing on the wheel hub side and push it home Specific tools and equipment ...

Page 235: ...ber top fixing screw 14 21 lbs ft 20 30 N m Shock absorber lower fixing screw 14 19 lbs ft 20 27 N m 11 9 Front Swing Arm Overhaul Remove the steering column Remove the shock absorber brake caliper bracket Using the special tool fitted with part 1 as shown in the figure remove pin and roller cage from their seat To remove the second roller cage fit the tool with part 2 on the opposite side to that...

Page 236: ...h mineral oil and half fill the needle casings with the recommended grease type Z2 Introduce the sealing ring on the pin and at the same time the roller bushing with wedging washer Remove the specific tool then part 5 guide which was partially expelled in the preceding fitting operation while leaving part 4 fitted Replace part 3 with part 16 on the shaft Operating on the tool handle push the wedgi...

Page 237: ... operate the handle to exert pressure until the washers are wedged onto the oscillating hub Remove the spacers part 17 fill the gap between the steering column and the oscillating hub with Z2 grease then place the dust covers in that space 1 Part 20 2 Part 17 3 Part21 11 10 Steering Column Ball Cage Bearings Overhaul Note This operation should be carried out exclusively in the case of extreme nece...

Page 238: ...igure Then from the top remove the lower steering bearing seat Specific tools and equipment Steering bearing removing punch 020004Y Using the specific tool remove the steering column ball cage bearing seat and the dust cover on the steering column as shown in the figure Use a mallet Specific tools and equipment Steering bearing removing punch 020004Y ...

Page 239: ...ing seat on the steering tube to abutment Specific tools and equipment Steering bearing removing punch 006029Y Using the specific tool install the steering column ball cage bearing seats on the head as shown in the figure Specific tools and equipment Steering bearing seat installer 001330Y ...

Page 240: ...nd the rear wheel axle fixing nut with spacer Remove the lower shock absorber fixing For re assembly perform the operations for removal in the reverse order tightening each fastener at the specified torque value Tightening torques Bracket crankcase fixing screw 14 18 lbs ft 20 25 N m Shock absorber lower fixing screw 23 29 lbs ft 33 41 N m Wheel axle nut 73 88 lbs ft 104 126 N m ...

Page 241: ...he rear rack Using a jack slightly lift the engine off the ground so to unload the rear suspensions Remove the silencer Loosen both lower shock absorber fastening bolts on crankcase and crankcase silencer bracket Loosen the two top shock absorber fastening screws top picture on the right and remove both shock absorbers ...

Page 242: ...13 Central Stand Suitably support the vehicle with a jack Remove the two stand return springs Loosen the nut indicated in the figure Remove the RH pin Remove the central stand Upon reassembly tighten the nut at the prescribed torque Tightening torques Central stand fastening bolt 18 21 lbs ft 25 30 N m 11 14 Inspecting the Rear Swing Arm Rest the vehicle on its central stand Remove the air cleaner...

Page 243: ...243 Remove the spring anchoring the swing arm to the frame as shown in the figure Remove the two screws fixing the pad support bracket to the frame ...

Page 244: ...244 Remove the RH and LH caps located under the footrest to access the pin fixing the swing arm to the body Carefully inspect the whole of the swing assembly ...

Page 245: ...ghtening the nuts onto the relevant pins at the correct tightening torques Tightening torques Swing arm bolt engine side 45 50 lbs ft 64 72 N m Swing arm bolt frame side 53 58 lbs ft 76 83 N m Silent block frame bracket screw 29 36 lbs ft 42 52 N m Swing arm bolt 23 29 lbs ft engine and frame side 33 41 N m 11 15 Swing Arm Overhaul Check that the silent block is not broken Replace if necessary Rem...

Page 246: ...on the frame side This is to ensure that the tool is centered with respect to the support Install a new silent block ensuring the alignment with the reference tooth Fit the silent block by properly matching the silent block chamfering with that of the bracket Using the specific tool install the silent block as shown in the figure ...

Page 247: ...owable clearance 0 059 in 1 50 mm To check the clearance on the frame side arm prepare the assembly using the frame side bolt and the two spacers from tool no 020229Y Alternatively use two standard washers for Ø 0 472 in 12 mm bolts and minimum external diameter and thickness of Ø 1 181 in 30 mm and 0 157 in 4 mm Check that the rotation is smooth Check the axial of the swing arm on the frame side ...

Page 248: ...n the figure Using a suitable pin remove the roller cases as shown in the figure Using the specific tool fit new cases being careful to position bearings with sealing rings facing outwards Specific tools and e quipment 0 59 in 15 mm punch for engine side swing arm cases 020244Y 0 71 in 18 mm punch for engine side swing arm cases 020115Y ...

Page 249: ...04 0 142 11 0 1 283 Frame side internal swing arm spacer length 004 0 417 11 0 1 290 Frame side swing arm plastic bushes diameter 002 0 138 0 0 05 3 5 Use TUTELA Z2 to grease the roller cases and the plastic bushes Insert the spacers Assemble the two arms with the relevant bolt in the position shown in the figure Orientate the bolt as shown in the figure Place the swing arm on the frame side with ...

Page 250: ...o screws shown in the picture Remove the seat 12 2 Removing the Steering Column Cover Remove the PIAGGIO badge Loosen the screw shown in the picture Carefully pull the cover 12 3 Removing the Front Handlebar Cover Remove the steering column cover Loosen the screw shown in the picture ...

Page 251: ...he Rear Handlebar Cover Remove the front handlebar cover Loosen the four screws shown in the picture Detach the speedometer cable Detach all electrical connections and remove the rear handlebar cover 12 5 Removing the Instrument Panel Remove the rear handlebar cover Loosen the four screws shown in the picture Remove the instrument panel ...

Page 252: ...en the two screws shown in the picture from the front leg shield Remove the expansion tank cover and its cap Loosen the screw shown in the picture positioned inside the glove box compartment Loosen the two screws shown in the picture positioned underneath the two side covers ...

Page 253: ...253 Loosen the four screws shown in the picture positioned at the bottom of the glove box panel Detach the seat opening electrical connection the fuse holder and the seat opening cable ...

Page 254: ...ngs Loosen the two screws shown in the picture and remove the fairing Follow the same operation for both left and right hand side 12 9 Removing the Footrest Remove the glove box panel Remove the battery compartm ent cover Remove the side fairings Loosen the screw shown in the picture positioned in the battery compartment ...

Page 255: ...ws on each side shown in the picture Loosen the two LH and RH footrest fixing screws Remove the two LH and RH lower plastic covers by loosening the screw as shown in the picture Remove the screws positioned underneath the rubber mat as shown in the picture ...

Page 256: ...ving the Luggage Carrier Remove the helmet compartment Loosen the two screws shown in the picture and remove the luggage carrier cover Loosen the six fixing screws shown in the figures and remove the luggage carrier ...

Page 257: ...wo license plate light fixing screws shown in the figure and remove the plastic flap Loosen the two fixing screws shown in the picture and remove the taillight 12 12 Removing the Helmet Compartment Open the seat and lift the helmet compartment bay ...

Page 258: ... removed by loosening the three fixing screws shown in the picture 12 14 Removing the Fuel Tank Remove the helmet compartment Remove the right hand side plastic fairing Remove the exhaust pipe Remove the luggage carrier Remove the top shock absorber fixing screws Loosen the two fuel tank fixing screws shown in the figure from the frame Detach the fuel level indicator cable shown in the figure ...

Page 259: ...e Remove the fuel tap clamps shown in the figure Remove the rear turn signal lights Lift the vehicle in order to obtain enough clearance between frame and engine such to remove the fuel tank from underneath the frame To reassemble the fuel tank follow the above operations in the reverse order ...

Page 260: ...by disconnecting the liquid inlet tube from the pump Remove the glove box panel Disconnect the inlet and outlet tubes from the RH radiator Loosen the radiator fixing screws shown in the figure Remove the radiator Detach the cooling liquid tube from the plastic air conveying vent Hence remove the conveying vent ...

Page 261: ...ions described above in the reverse order paying particular attention in using new clamps for all the cooling liquid piping connections and in properly refilling the cooling circuit 12 16 Removing the Rear Mudguard Remove the air filter Loosen the fixing screw shown in the picture Remove the mudguard 12 17 Removing the Turn Signal Lights Loosen the screw shown in the figure and remove the front tu...

Page 262: ...the figure and remove the rear turn signal light 12 18 Removing the Electrical Opening Seat System Remove the helmet compartment Loosen the two nuts shown in the figure Detach the electrical cable from the clamps shown in the figure ...

Page 263: ...g cable Remove the seat opening cable manual control Detach the electrical connector from the seat opening actuator Loosen the two screws shown in the figure Remove the return spring Remove the actuator from the support bracket ...

Page 264: ...ights front and rear and warning lights on instrument panel Instrument panel light fuel and cooling liquid temperature indicators Horn Electric starter Emergency engine cut off switch Electrical seat opening button Warning The battery must be charged before use to ensure optimal performance An inadequate electrolyte level will result in a premature failure of the battery Warning When installing th...

Page 265: ...ERIES AWAY FROM CHILDREN Warning Never use a fuse with a higher rating that the prescribed value The use of unsuitably rated fuses can result in widespread damage to the vehicle including fire 13 4 Checking the Levels Brake fluid Rear hub Engine oil Cooling liquid 13 5 Road Test Cold start Instruments Throttle response Vehicle stability in acceleration and braking Front and rear brake efficiency F...

Page 266: ...r documents inspection toolkit license plate locks tires inflation pressure mirrors and accessories Warning Check and adjust the tire inflation pressure only when the tires are at ambient temperature Warning Over inflated tires can burst Never exceed the prescribed inflation pressure ...

Page 267: ...oil Replacement 2 003064 10 Engine fixing Nut tightening 3 003057 10 14 2 Crankcase Description Op Code Time Half crankcase gasket Replacement 1 001153 140 Engine crankcase Replacement 2 001133 200 14 3 Crankshaft Description Op Code Time Flywheel side oil seal Replacement 1 001099 40 Engine crankshaft Replacement 2 001117 160 ...

Page 268: ...r Head and Valves Description Op Code Time Cylinder Head Assembly Replacement 1 001126 130 Valves Replacement 2 001045 130 Valves Adjustment 3 001049 40 Head Gasket Replacement 4 001056 120 Thermistore Replacement 5 001083 15 Thermostat Replacement 6 001057 20 14 6 Camshaft Description Op Code Time Valve rockers Replacement 1 001148 120 Camshaft Replacement 2 001044 120 ...

Page 269: ...nt 3 001088 40 Oil vapor recovery pipe Replacement 4 001074 10 14 8 Chain Tensioner By Pass Valve Description Op Code Time Chain tensioner Overhaul and Replacement 1 001129 10 Lubrication by pass valve Replacement 2 001124 30 14 9 Oil Filter Description Op Code Time Oil filter Replacement 1 001123 10 Oil pressure sensor Replacement 2 001160 40 ...

Page 270: ...0 Clutch drum Replacement 4 001155 20 14 11 Pump Assembly Oil Sump Description Op Code Time Chain guide shoe Replacement 1 001125 140 Timing belt chain Replacement 2 001051 140 Oil pump Overhaul 3 001042 70 Oil pump Replacement 4 001112 60 Oil pump chain Replacement 5 001122 60 Oil sump Replacement 6 001130 30 Chain cover port Replacement 7 001172 30 ...

Page 271: ... Replacement 2 001156 60 Gearbox oil Replacement 3 003065 15 Rear wheel axle Replacement 4 004125 45 14 13 Driving Pulley Description Op Code Time Driving half pulley Replacement 1 001086 25 Driving belt Replacement 2 001011 25 Driving pulley Removal and reassembly 3 001066 25 Driving pulley Overhaul 4 001006 25 ...

Page 272: ...ent 3 001141 20 14 15 Kick Starter Transmission Cover and Transmission Cooling Description Op Code Time Transmission cover bearing Replacement 1 001135 25 Transmission cover Replacement 2 001096 20 Transmission air inlet Replacement 3 001131 20 14 16 Transmission Cooling Air Inlet Description Op Code Time Transmission air inlet pipe Replacement 1 001132 10 ...

Page 273: ...dary air filter Replacement 5 001161 30 Secondary air filter box Replacement 6 001162 30 Rotor Replacement 7 001173 45 14 18 Carburetor Description Op Code Time Intake manifold Replacement 1 001013 10 Carburetor heating pipes Replacement 2 007020 20 Carburetor Overhaul 3 001008 30 Carburetor Replacement 4 001063 20 Automatic choke Replacement 5 001081 15 Carburetor Adjustment 6 003058 10 Exhaust e...

Page 274: ...ir filter Replacement Cleaning 1 001014 20 Air filter box Replacement 2 001015 15 Carburetor air box bellow Replacement 3 004122 20 14 20 Silencer Description Op Code Time Silencer Replacement 1 001009 15 Silencer protection Replacement 2 001095 10 ...

Page 275: ...4085 5 Horn Replacement 3 004149 5 Spoiler Replacement 4 004053 5 Passenger footrest Removal and reassembly 5 004015 5 Shield edge Replacement 6 004023 45 Badges Replacement 7 004159 10 14 22 Central Stand Description Op Code Time Side stand Replacement non US 1 Central stand Replacement 2 004004 10 ...

Page 276: ...1 005007 20 Footrest Replacement 2 004079 40 Battery compartment Replacement 3 004071 10 Battery cover Replacement 4 005046 5 Footrest rubber Replacement 5 004078 5 14 24 Glove Box Description Op Code Time Glove box Replacement 1 004083 25 Glove box flap Replacement 2 004081 25 ...

Page 277: ...ent 3 005048 10 14 26 Front Fender and Rear Mudguard Description Op Code Time Front fender Replacement 1 004002 45 Rear mudguard Replacement 2 004009 20 Front suspension cover Replacement 3 003044 10 14 27 Fuel Tank Description Op Code Time Fuel tank Replacement 1 004005 50 Tank float Replacement 2 005010 45 Fuel tank bleed Replacement 3 004109 10 Fuel tap Replacement 4 004007 10 ...

Page 278: ...ent 4 007014 55 Tank radiator pipe Replacement 5 007013 40 Coolant pipe Replacement 6 007003 60 Coolant and air vent Replacement 7 001052 20 14 29 Fuel Pump Description Op Code Time Fuel pump Replacement 1 004073 15 Fuel pump tank tube Replacement 2 004089 10 Fuel filter Replacement 3 004072 10 Vacuum fuel pump tube Replacement 4 004086 10 Pump carburetor tube Replacement 5 004086 10 ...

Page 279: ...nt 2 003073 25 14 31 Front Suspension Description Op Code Time Front shock absorber Removal and reassembly 1 003011 20 Steering column Replacement 2 003045 60 Front suspension Overhaul 3 003010 100 Brake caliper suspension bracket Replacement 4 003035 25 Front wheel hub bearings Replacement 5 003034 40 Odometer reel Replacement 6 001064 15 ...

Page 280: ...Description Op Code Time Rear shock absorber Removal and reassembly 1 003007 20 14 33 Handlebar Covers Description Op Code Time Handlebar cover front side Replacement 1 004018 15 Handlebar cover back side Replacement 2 004019 20 ...

Page 281: ... Replacement 4 005017 20 LH handgrip Replacement 5 002059 10 RH handgrip Replacement 6 002071 10 Counterweight Replacement 7 003059 5 Throttle sleeve Replacement 8 002060 30 Complete throttle cable Replacement 9 002063 50 Throttle cable Adjustment 10 003061 10 Brake lever Replacement 11 002037 15 14 35 Swing Arm Description Op Code Time Engine Frame swing arm Replacement 1 001072 50 Silent block R...

Page 282: ...bly 4 020039 20 Rear brake caliper Removal and reassembly 5 002048 35 Rear brake caliper Overhaul 6 002068 50 Front brake tube Removal and reassembly 7 002021 45 Rear brake tube Removal and reassembly 8 002020 50 Rear brake pads Removal and reassembly 9 002002 30 Front brake pads Removal and reassembly 10 002007 15 Front brake fluid Replacement 11 002047 15 Rear brake fluid Replacement 12 002080 1...

Page 283: ...ription Op Code Time Saddle opening cable Replacement 1 002083 45 Lock cable for saddle opening Replacement 2 002092 20 Lock for saddle opening Replacement 3 004158 20 Immobilizer antenna Replacement 4 005072 30 Electric device for saddle opening replacement 5 005099 20 Saddle lock Replacement 6 004054 10 Steering lock Replacement 7 004010 35 Ignition switch Replacement 8 005016 35 ...

Page 284: ...rt button Replacement 3 005041 20 Engine cut off switch Replacement 4 005077 20 Turn signal switch replacement 5 005006 20 Horn button Replacement 6 005040 20 Saddle opening button Replacement 7 005121 25 Ignition switch Replacement 8 005039 20 Lights switch Replacement 9 005078 25 Panel warning lights Replacement 10 005038 10 Clock battery Replacement 11 005076 15 ...

Page 285: ...al bulb Replacement 4 005067 5 Headlight bulb Replacement 5 005008 10 Taillight bulb Replacement 6 005066 10 Plate light bulb Replacement 7 005031 10 Brake light bulb Replacement 8 005090 10 Rear turn signal bulb Replacement 9 005068 5 Rear turn signal light Replacement 10 005022 5 Front turn signal light Replacement 11 005012 5 Turn signal lens Replacement 12 005091 5 ...

Page 286: ...ment 5 001023 40 Voltage regulator Replacement 6 005009 20 Electrical circuit Replacement 7 005001 120 Electrical circuit Overhaul 8 005114 30 Headlight relay Replacement 9 005035 15 Starting relay Replacement 10 005011 15 Fuse holder Replacement 11 005054 25 Fuse holder board Replacement 12 005019 25 Complete odo speedometer cable Replacement 13 002051 40 Battery fuse Replacement 14 005024 10 Bat...

Page 287: ...03037 15 Front tire Replacement 5 003047 15 Front tire Check 6 003063 5 14 43 Rear Wheel Description Op Code Time Rear wheel Replacement 1 001016 20 Rear tire Replacement 2 004126 25 Rear wheel rim Removal and reassembly 3 001071 25 Rear brake disk Replacement 4 002070 35 Silencer suspension support bracket Replacement 5 003077 25 Rear wheel hub Replacement 6 002028 35 Rear tire pressure Check 7 0...

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