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NACIONAL MOTOR, S.A.U.

DERBI Derbi -
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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE
INDEX OF TOPICS

CHARACTERISTICS CHAR
Characteristics

Rules

Safety rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CAUTION
USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START-
ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE
ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE
COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL
GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM
PARTS.
DO NOT HOLD ANY MECHANICAL OR OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOT-
ER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND
EVEN TOXIC.
CARBON MONOXIDE
If you need to keep the engine running in order to carry out any procedure, please ensure that you do
so in an open or very well ventilated area.
Never let the engine run in an enclosed area.
If you do work in an enclosed area, make sure to use a smoke-extraction system.
CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
FUEL
CAUTION

FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EX-
PLOSIVE UNDER SPECIFIC CONDITIONS.
IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PRO-
CEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF.
DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT
WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE
OR EXPLODE.
CAUTION

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.


CAUTION

KEEP OUT OF THE REACH OF CHILDREN.


HIGH-TEMPERATURE COMPONENTS

CHAR - 6
Characteristics

The engine and the components of the exhaust system can get very hot and remain hot for some time
even after the engine has been switched off.
Before handling these components, make sure that you are wearing insulating gloves or wait until the
engine and the exhaust system have cooled down.

TRANSMISSION OIL AND USED FORK OIL


CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.


THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR
LONG PERIODS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.
CAUTION

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.


CAUTION

KEEP OUT OF THE REACH OF CHILDREN.


BRAKE FLUID
CAUTION

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.
ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM.
THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.
IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
CAUTION

KEEP OUT OF THE REACH OF CHILDREN.


HYDROGEN GAS AND BATTERY ELECTROLYTE
CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,


IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.
WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-
TECTIVE APPAREL.
IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT
COOL WATER.
IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS
OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,

CHAR - 7
Characteristics

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL-
IST AS SOON AS POSSIBLE.
IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL-
LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE-
LY.
THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-
RETTES OR ANY OTHER HEAT SOURCE.
ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
CAUTION

KEEP OUT OF THE REACH OF CHILDREN.


CAUTION

THE BATTERY LIQUID IS CORROSIVE.


DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.
ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-
VATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION


When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
CAUTION
UNLESS OTHERWISE INDICATED, REFIT THE UNIT FOLLOWING THE REMOVAL STEPS BUT
IN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE
OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY RE-
MOVAL OF COMPONENTS. DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES.
NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER.
DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTS
AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD.
DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUT
ELECTRICAL WELDING WORK.
BEFORE REMOVING COMPONENTS

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this scooter, as required.

REMOVAL OF COMPONENTS

Do not loosen and/or tighten screws and nuts using pliers or other tools than the specially
designed wrench.
Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
Each component needs to be clearly marked in order to be identified during reassembly.
Clean and wash the dismantled components carefully using a low-flammability detergent.

CHAR - 8
Characteristics

Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
Some components must be used together or replaced altogether.
Keep away from heat sources.

REASSEMBLING COMPONENTS
CAUTION

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH
A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED
MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.
AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS
SEAT.
DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.
NOTE
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH-
ERWISE THEY NEED REPLACING.
Use only ORIGINAL Derbi SPARE PARTS.
Comply with lubricant and consumables usage guidelines.
Lubricate parts (whenever possible) before refitting them.
When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and
screws with new ones if their tread is damaged.
When fitting bearings, make sure to lubricate them well.
Check that each component is fitted correctly.
After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-
hicle on private grounds or in an area with low traffic density.
Clean all coupling surfaces, oil guard rims and washers before refitting them. Apply a light
layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the
bearings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below as non-compliance with the procedure
so described causes irreparable damage to both the connector and the cable harness: Press the rele-
vant safety hooks, if any.
CAUTION

TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.


Grip the two connectors and disconnect them by pulling them in opposite directions.

CHAR - 9
Characteristics

In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a
pressurised air jet.
Make sure that the cables are correctly linked to the connector's internal terminal ends.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY
ROUND.
Then fit the two connectors making sure that they couple correctly (if the relevant hooks are
provided, you will hear them "click" into place).

TIGHTENING TORQUE
CAUTION

DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS,


BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN
ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS.
IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY
BECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COM-
PROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK
OF SERIOUS INJURY OR DEATH.
BRAKE FLUID
CAUTION
DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQ-
UIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM.
DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT
HAVE BEEN OPEN FOR A PROLONGED TIME.
SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE
TO FAULTS IN THE HYDRAULIC CIRCUIT.
MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT
SMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND IN-
SPECTION OPERATIONS.
CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN.
ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY INTO THE CIRCUIT.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT.
DISC BRAKE
CAUTION
ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS.
SOILED PADS MUST BE REMOVED AND REPLACED. A SOILED DISC OR A DISC WITH TRACES
OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT.
IF THE SCOOTER IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS, OR
IF IT IS USED FOR SPORTS APPLICATION, HALVE THE SERVICE INTERVALS.
COOLANT
The cooling of the engine is by forced liquid circulation. The coolant liquid is made up of 50% de-ionised
water and antifreeze solution in a base of ethylene glycol and corrosion inhibitors. The product recom-
mended in the 'Recommended products table' is already mixed and ready to use.

CHAR - 10
Characteristics

For the best functioning of the engine the temperature of the coolant fluid should register in the central
zone of the appropriate gauge. If the needle enters the red zone, stop the engine, allow it to cool, and
check the level of the fluid; if it is normal, contact an Official Derbi Dealer.
CAUTION

DO NOT USE YOUR VEHICLE IF THE COOLANT LEVEL IS BELOW THE MINIMUM LEVEL
MARKED "MIN".
CAUTION

COOLANT IS TOXIC IF INGESTED; CONTACT WITH YOUR EYES OR SKIN MAY CAUSE IRRITA-
TION. IF THE FLUID GETS IN CONTACT WITH THE EYES OR SKIN, RINSE REPEATEDLY WITH
PLENTY OF WATER AND SEEK MEDICAL ADVICE. IF SWALLOWED, INDUCE VOMITING, RINSE
MOUTH AND THROAT WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE IMMEDIATELY.
CAUTION

DO NOT REMOVE THE EXPANSION TANK PLUG WHEN THE ENGINE IS HOT, SINCE COOLANT
IS UNDER PRESSURE AND VERY HOT. CONTACT WITH SKIN OR CLOTHES MAY CAUSE SE-
VERE BURNS AND/OR INJURIES.
TYRES
CAUTION
CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT
ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS.
THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS
SLIPPERY. DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES (MILES).
NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES.
IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUEL
THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER.
A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT
SIMPLY CLEANED.
DO NOT FIT TYRES WITH INNER TUBES ON RIMS FOR TUBELESS TYRES AND VICE VERSA.

Vehicle identification

Chassis number
The chassis number is stamped on the chassis
central bar. Remove the indicated cap placed in-
side the front glove-box in order to read this num-
ber.

CHAR - 11
Characteristics

Engine number
The engine number is stamped near the rear
shock absorber lower support.
CAUTION
ALTERING IDENTIFICATION NUMBERS CAN BE SERI-
OUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING
THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE
THE WARRANTY.

Dimensions and mass

SIZES
Specification Desc./Quantity
Max. length 1965 mm
Max. length (to brake levers (to mirrors)) 720 mm (890 mm)
Max. height (to the rear-view mirrors) 1.143 mm
Saddle height 790 mm
Wheelbase 1360 mm
Minimum ground clearance 130 mm
Kerb weight 148 kg

Engine

ENGINE TECHNICAL DATA


Specification Desc./Quantity
Engine model M281M (125)
M282M (200)
Engine type Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication
system, overhead camshaft.
Valve quantity 4
Cylinder quantity 1
Overall engine capacity 124 cm (125)
198 cm (200)
Bore/stroke 57 mm / 48.6 mm (125)
72 mm / 48.6 mm (200)
Compression ratio 12.0 0.5 : 1 (125)
11.5 0.5 : 1 (200)
MAX power 11 kW at 10,000 rpm (125)
14 kW at 8,500 rpm (200)
MAX. torque 11.7 Nm at 7,500 rpm (125)
19 Nm at 6,500 rpm (200)
Start-up Electric
Engine revs at idle speed 1600 100 rpm
Clutch Automatic centrifugal dry clutch
Lubrication system Wet sump forced lubrication system.
Cooling forced-circulation air cooling driven by a centrifugal pump
Valve clearance Inlet: 0.10
Outlet: 0.15
Carburettor model (125): CVK7 30 Keihin
Carburettor model (200): CVK7 30 Keihin
WVF7 29 WALBRO
Supply Vacuum pump
Fuel Use premium unleaded petrol only, with minimum octane rating
of 95 (NORM) and 85 (NOMM).
IGNITION Capacitive discharge ignition, variable advance
Ignition advance (125) Variable ignition advance by microprocessor:

CHAR - 12
Characteristics

Specification Desc./Quantity
10 1 to 2,000 rpm
34 1 from 4,500 to 10,000 rpm
Ignition advance (200) Variable (before TDC) from:
10 1 to 2,000 rpm
32 1 to 6,500 rpm
Spark plug NGK CR7EB
Spark plug electrode gap 0.7 - 0.8 mm

Transmission

TRANSMISSION
Specification Desc./Quantity
Gear continuous and automatic variator
Primary drive V-belt
Secondary With gears
Engine/wheel total ratio 1/6.36 (125)
1/6.54 (200)
Minimum ratio for continuos transmission 36.5 (125)
22.36 (200)
Maximum ratio for continuos transmission 10.95 (125)
7.88 (200)

Capacities

CAPACITY
Specification Desc./Quantity
Fuel (reserve included) 9l
Fuel reserve 1.5 l
Engine oil - engine oil change and engine oil filter replacement 1100 cm
Transmission oil 250 cm
Fork oil 135
1 cm per stem
Depth of fork oil level from the rim / without spring / fork included 99 1.5 mm
Coolant 1.5 l (50% water + 50% ethylene glycol antifreeze fluid)
Seats 2
Vehicle max. load (rider + passenger + luggage) 210 kg

Electrical system

BULBS/WARNING LIGHTS
Specification Desc./Quantity
1 High-/low-beam bulb 12 V - 55 W - H7
2 Tail light bulb 12V - 5W
3 Front turn indicator bulbs 12 V - 10 W (Amber)
4 Rear turn indicator bulbs 12 V - 10 W (White)
5 Rear tail light /stop light bulb 12 V - 5/21 W (Red)
6 License plate light bulb 12V - 5W
7 Instrument panel lighting bulb LED
8 Turn indicator warning light LED
9 High-beam warning light LED
10 Low fuel warning light LED
11 Engine oil pressure warning light LED
12 High coolant temperature gauge warning light LED

ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 10 Ah

CHAR - 13
Characteristics

Specification Desc./Quantity
(Permanent magnet) Generator 12V - 180W

Frame and suspensions

CHASSIS AND SUSPENSIONS


Specification Desc./Quantity
Size "A" 423.5 mm
Size "B" 479 mm
Trail 86.2 mm
Chassis type High-strength steel tubular chassis, single spar at the front, su-
perimposed double cradle at the rear.
Steering inclination angle 26.5
Front suspension Hydraulic action telescopic fork
Front suspension travel 100 mm
Rear suspension hydraulic action double-acting shock absorber, adjustable pre-
loading
Rear suspension travel 80 mm

Brakes

BRAKES
Specification Desc./Quantity
Front brake 260-mm disc brake with hydraulic transmission
Rear brake 220-mm disc brake with hydraulic transmission

Wheels and tyres

WHEELS AND TYRES


Specification Desc./Quantity
Wheel rims Made of light alloy
Front wheel rim 2.75 x 15"
Rear wheel rim 3.00 x 15"
Tyres Without inner tube (Tubeless)
Front tyre 120/70 - 15'' 56P
Rear tyre 130/80 - 15'' 63P
Rear tyre standard inflation pressure 200 kPa (2.0 bar)
Front tyre standard inflation pressure 200 kPa (2.0 bar)
Front tyre standard inflation pressure with passenger 200 kPa (2.0 bar)
Rear tyre standard inflation pressure with passenger 230 kPa (2.3 bar)

CHAR - 14
Characteristics

Carburettor

KEY:
1. Minimum jet
2. Maximum jet
3. Idle air set screw
4. Tapered pin
5. Throttle valve return spring
6. Float chamber assy
7. Starter cover
8. Cover
9. Screw
10. Screw
11. Fuel closing float needle
12. Diaphragm
13. Float kit
14. Complete automatic starter
15. Spring
16. Cap
17. Washer
18. Seeger ring
19. Spring

CHAR - 15
Characteristics

20. Washer
21. Acceleration pump kit

125cc Version

Kehin

CARBURETTOR 125 CC
Specification Desc./Quantity
Model CVK7 30 Keihin
Diffuser 29 mm
Engine-side coupling 40 mm
Float
Petrol inlet valve needle seat 1.2
Start-up air inlet hole 150
Start-up jet 42
Minimum jet 35
Idle air screw open in turns 2
Minimum air hole 130
Maximum air hole 70
Maximum jet 105
Throttle valve Standard
Sprayer 2.8 mm
Tapered pin NDVA
Notch

200cc Version

Kehin

CARBURETTOR 200 CC
Specification Desc./Quantity
Model CVK7 30 Keihin
Diffuser 29 mm
Engine-side coupling 40 mm
Float
Petrol inlet valve needle seat 1.2
Start-up air inlet hole 150
Start-up jet 42
Minimum jet 38
Idle air screw open in turns 2
Minimum air hole 115
Maximum air hole 70
Maximum jet 100
Throttle valve Standard
Sprayer 2.8 mm
Tapered pin NDVA
Notch

Tightening Torques

HANDLEBAR
Name Torque in Nm
Handlebar to fork retainer 4820%

CHAR - 16
Characteristics

Name Torque in Nm
Safety screw 2020%
Steering set nut 1520%
Steering series fixing lock nut 11020%
Instrument panel support to handlebar retainer 620%
Mirror supports to handlebar retainer 5220%
Mirrors retainer 2520%

CHASSIS
Name Torque in Nm
License plate holder curved support to chassis retainer 2520%
Passenger grab handle to chassis retainer 2520%
Horn to chassis retainer 1020%
Regulator to chassis retainer 1020%
Switch to chassis retainer 1020%
Fuel tank to chassis retainer 1020%
Helmet compartment to chassis retainer 520%
Air deflector to chassis retainer 520%
Coil to chassis retainer 520%

ELECTRICAL SYSTEM
Name Torque in Nm
Starter motor cable retainer 520%
Battery to relay retainer 420%
Starter motor on relay retainer 420%
Battery cable harness ground lead retainer 1020%

SADDLE
Name Torque in Nm
Hinge on saddle retainer 720%

LOCKS
Name Torque in Nm
Glove-box lock on cover retainer 420%
Saddle lock on right and left half-tail sections retainer 320%
Saddle lock on helmet compartment retainer 520%

INSTRUMENT PANEL
Name Torque in Nm
Instrument panel to rear panel retainer 0.820%
Instrument panel to instrument panel support retainer 4.520%
Rear panel to handlebar retainer 120%
Front panel to lower clamp retainer 120%
Front panel to rear panel retainer 320%
Lower clamp to rear panel retainer 120%
Left and right tool holder retainer 520%

REAR BODYWORK
Name Torque in Nm
Retroreflector to license plate holder retainer 1.520%
License plate to license plate holder retainer 120%
Rear taillight to right and left half-tail sections retainer 120%
Front retainer for right and left half-tail sections on helmet com- 420%
partment
Rear retainer for right and left half-tail sections on helmet com- 120%
partment
Rear light cover on license plate holder retainer 120%
Rear light cover on helmet compartment retainer 6
Rear light cover on tail sections retainer 120%
License plate holder on right and left half-tail sections retainer 320%
License plate holder on rear mudguard chassis retainer 520%
Luggage carrier cover on luggage carrier retainer 120%

CHAR - 17
Characteristics

Name Torque in Nm
Retainer between passenger grab handle cover and passenger 120%
grab handle
Right and left half-tail sections on helmet compartment retainer 120%
Fuel probe lid on helmet compartment retainer 120%
Retainer for lower lock of right and left half-tail sections on right 320%
and left half-tail sections

CENTRAL BODYWORK
Name Torque in Nm
Central inspection cover on helmet compartment retainer 120%
Central inspection cover on right and left fairings retainer 320
Left side inspection cover retainer 320%
Right side inspection cover retainer 320%
Battery cover retainer 320%
Footrest retainer 320%
Right and left lower shield retainer 320%
Glove-box lid on internal legshield retainer 120%
Internal legshield to external legshield retainer 120%
Glove-box net on internal legshield retainer 120%
Glove-box lid reinforcing retainer 120%
Bag hook retainer 120%
Air intake on internal legshield retainer 120%

FRONT AND REAR BRAKE


Name Torque in Nm
Calliper on fork retainer 2520%
Calliper on muffler plate retainer 2520%
Pipe cable guide on link rod retainer 1020%
Pipe cable guide on air deflector retainer 520%
Right and left pump on handlebar retainer 1020%
Rear calliper support to muffler plate retainer 2520%
Rear calliper support on muffler plate retainer 2520%
Front pipe cable guide on fork retainer 1020%

FRONT BODYWORK
Name Torque in Nm
Right and left air intake on shield retainer 120%
Right and left turn indicators on external legshield retainer 120%
Front headlamp on external legshield retainer 120%
External legshield on cover retainer 120%
External legshield on shield retainer 120%
Front mudguard clamp on fork retainer 120%
External legshield on under-footrest retainer 320%
Front mudguard on clamps retainer 520%
Case on internal legshield retainer 220%

FILTER CASING
Name Torque in Nm
Sleeve on carburettor retainer 220%
Sleeve on filter housing retainer 220%
Filter housing on engine retainer 820%

COOLING UNIT
Name Torque in Nm
Thermal switch retainer 2020%
Head pipe on radiator retainer 220%
Pump pipe on radiator retainer 220%
Radiator on bulkhead retainer 720%
Electric fan on radiator retainer 120%
Expansion tank on air deflector retainer 420%

CHAR - 18
Characteristics

FRONT WHEEL
Name Torque in Nm
Pin retainer 5020%
Safety screw retainer 1020%

LINK ROD
Name Torque in Nm
Connecting rod to chassis retainer 6020%
Connecting rod to engine retainer 4020%
Chassis connecting rod on engine connecting rod retainer 6020%
Silent-block on chassis retainer 5020%

EXHAUST
Name Torque in Nm
Manifold to engine retainer 1520%
Muffler to manifold retainer 1620%
Muffler on plate retainer 2520%
Protection on muffler retainer 720%

REAR WHEEL
Name Torque in Nm
Rear wheel retainer 11020%
Speed sensor screw retainer 1020%
Speed sensor on muffler plate retainer 1020%

STAND
Name Torque in Nm
Stand to engine retainer 2720%

ENGINE
Name Torque in Nm
Muffler plate on engine 2520%
Fuel breather pipe cable guide on crankcase 1020%
Anti-vibration roller 12 16
Driven pulley shaft nut 54 60
Clutch assembly nut on driven pulley 55 60
Driving pulley nut 75 83
Flywheel nut 54 60
Oil filter fitting on crankcase 27 33
Minimum oil pressure sensor 12 14
engine oil drainage plug/mesh filter 24 30
oil pump driving crown gear screw 10 14
Timing chain tensioner support screw 11 13
Engine crankcase coupling screws 11 13
Rear hub cover screws 24 27
Oil pump cover screws 0.7 0.9
Transmission cover screws 11 13
Oil sump screws 10 14
Screws fixing oil pump to crankcase 56
Stator unit screws () 34
Starter motor screws 11 13
Screws for engine crankcase internal bulkhead (transmission- 46
side half shaft)

REAR SUSPENSION
Name Torque in Nm
Right and left shock absorber to chassis retainer 2520%
Shock absorber on engine bracket retainer 4020%
Shock absorber on muffler plate retainer 4020%
Shock absorber bracket on engine retainer 2520%

CHAR - 19
Characteristics

FUEL SUPPLY SYSTEM


Name Torque in Nm
Probe to tank retainer 1.520%
Fuel coupling clamp retainer 120%
Tank to helmet compartment retainer 220%
Petrol pump on helmet compartment retainer 220%

Overhaul data

Assembly clearances

Cylinder - piston assy.


125 cm Version

COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder A 56.997 57.004 56.945 56.952 0.045 - 0.059
Cylinder B 57.004 57.011 56.952 56.959 0.045 - 0.059
Piston C 57.011 57.018 56.959 56.966 0.045 - 0.059
Piston D 57.018 57.025 56.966 56.973 0.045 - 0.059
Cylinder 1st Oversize A1 57.197 57.204 57.145 57.152 0.045 - 0.059
Cylinder 1st Oversize B1 57.204 57.211 57.152 57.159 0.045 - 0.059
Piston 1st Oversize C1 57.211 57.218 57.159 57.166 0.045 - 0.059
Piston 1st Oversize D1 57.218 57.225 57.166 57.173 0.045 - 0.059
Cylinder 2nd Oversize A2 57.397 57.404 57.345 57.352 0.045 - 0.059
Cylinder 2nd Oversize B2 57.404 57.411 57.352 57.359 0.045 - 0.059
Piston 2nd Oversize C2 57.411 57.418 57.359 57.366 0.045 - 0.059
Piston 2nd Oversize D2 57.418 57.425 57.366 57.373 0.045 - 0.059
Cylinder 3rd Oversize A3 57.597 57.604 57.545 57.552 0.045 - 0.059

CHAR - 20
Characteristics

Name Initials Cylinder Piston Play on fitting


Cylinder 3rd Oversize B3 57.604 57.611 57.552 57.559 0.045 - 0.059
Piston 3rd Oversize C3 57.611 57.618 57.559 57.566 0.045 - 0.059
Piston 3rd Oversize D3 57.618 57.625 57.566 57.573 0.045 - 0.059

200 cm Version

COUPLING CATEGORIES (WITH ALUMINIUM CYLINDER)


Name Initials Cylinder Piston Play on fitting
Cylinder/Piston A 71.990 71.997 71.953 71.960 0.030 - 0.044
Cylinder/Piston B 71.997 72.004 71.960 71.967 0.030 - 0.044
Cylinder/Piston C 72.004 72.011 71.967 71.974 0.030 - 0.044
Cylinder/Piston D 72.011 72.018 71.974 71.981 0.030 - 0.044

COUPLING CATEGORIES (WITH CAST-IRON CYLINDER)


Name Initials Cylinder Piston Play on fitting
Cylinder/Piston M 72 72.007 71.953 71.960 0.040 - 0.054
Cylinder/Piston N 72.007 72.014 71.960 71.967 0.040 - 0.054
Cylinder/Piston O 72.014 72.021 71.967 71.974 0.040 - 0.054
Cylinder/Piston P 72.021 72.026 71.974 71.981 0.040 - 0.054

Piston rings
125 cm Version

CHAR - 21
Characteristics

ENGINE SEALING RINGS


Name Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 0.30
Oil scraper ring 57 x 1 A 0.10 0.30
Oil scraper ring 57 x 2.5 A 0.15 0.35

ENGINE SEALING RINGS (1 ST OVERSIZE)


Name Description Dimensions Initials Quantity
Compression ring 1st 57.2 x 1 A 0.15 0.30
Oversize
Oil scraper ring 1st 57.2 x 1 A 0.10 0.30
Oversize
Oil scraper ring 1st 57.2 x 2.5 A 0.15 0.35
Oversize

ENGINE SEALING RINGS (2 ND OVERSIZE)


Name Description Dimensions Initials Quantity
Compression ring 2nd 57.4 x 1 A 0.15 0.30
Oversize
Oil scraper ring 2nd 57.4 x 1 A 0.10 0.30
Oversize
Oil scraper ring 2nd 57.4 x 2.5 A 0.15 0.35
Oversize

ENGINE SEALING RINGS (3 RD OVERSIZE)


Name Description Dimensions Initials Quantity
Compression ring 3rd 57.6 x 1 A 0.15 0.30
Oversize
Oil scraper ring 3rd 57.6 x 1 A
Oversize
Oil scraper ring 3rd 57.6 x 2.5 A 0.15 0.35
Oversize

200 cm Version

CHAR - 22
Characteristics

ENGINE SEALING RINGS


Name Description Dimensions Initials Quantity
Compression ring 72x1.5 A 0.15 0.30
Oil scraper ring 72 x 1 A 0.10 0.40
Oil scraper ring 72 x 2.5 A 0.20 0.40

Crankcase - crankshaft - connecting rod

CRANKSHAFT HALF-BEARINGS
Name Description Dimensions Initials Quantity
Crankshaft half-bear- B Type - blue 1.973 1.976
ings
Crankshaft half-bear- C Type - yellow 1.976 1.979
ings
Crankshaft half-bearing E Type - green 1.979 1.982

CRANKCASE - CRANKSHAFT COUPLINGS


Name Description Dimensions Initials Quantity
Crankshaft type 1- E-E
Crankcase type 1
Crankshaft type 1 - C-C
Crankcase type 2
Crankshaft type 2 - C-C
Crankcase type 1
Crankshaft type 2 - B-B
Crankcase type 2

CRANKSHAFT - CRANKCASE
Name Description Dimensions Initials Quantity
Crankshaft Class 1 28.998 29.004
Crankshaft Class 2 29.004 29.010
Crankcase Class 1 32.959 32.965
Crankcase Class 2 32.953 32.959

CHAR - 23
Characteristics

Fitting clearances
Crankshaft/crankcase axial clearance (H):
0.15 0.40 mm (when cold)

CHAR - 24
Characteristics

CRANKSHAFT / CRANKCASE AXIAL CLEARANCE


Name Description Dimensions Initials Quantity
Half shaft, transmission 16.6 +0-0.05 A D = 0.20 0.50
side
Half shaft, flywheel side 16.6 +0-0.05 B D = 0.20 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 0.50
Spacer tool 51.4 +0.05 E D = 0.20 0.50

Slot packing system


125 cm Version

Characteristic
Compression ratio
12 0.5 : 1

Distance A to be measured is a value of piston protrusion, it indicates how deep the piston crown
protrudes out of the plane formed by the cylinder crown. The further the piston protrudes out of the
cylinder, the thicker the base gasket to be used should be (to compensate the compression ratio) and
vice versa.
NOTE
DISTANCE A, MEASURED WITH THE PISTON AT THE TOP DEAD CENTER, MUST BE TAKEN
WITH NO GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESET-
TING THE DIAL GAUGE, WITH ITS SUPPORT ON A GROUND SURFACE.

CHAR - 25
Characteristics

METAL HEAD GASKET (0.3)


Name Measure A Thickness
Shimming - Cylinder 67.8 - Head gasket 1.40 1.65 0.4 0.05
0.3 - Base gasket 0.4
Shimming - Cylinder 67.8 - Head gasket 1.65 1.90 0.6 0.05
0.3 - Base gasket 0.6

200 cm Version

Characteristic
Compression ratio
11.5 0.5: 1

Distance A to be measured is a value of piston protrusion, it indicates how deep the piston crown
protrudes out of the plane formed by the cylinder crown. The further the piston protrudes out of the
cylinder, the thicker the base gasket to be used should be (to compensate the compression ratio) and
vice versa.
NOTE
DISTANCE A, MEASURED WITH THE PISTON AT THE TOP DEAD CENTER, MUST BE TAKEN
WITH NO GASKET FITTED BETWEEN THE CRANKCASE AND CYLINDER AND AFTER RESET-
TING THE DIAL GAUGE, WITH ITS SUPPORT ON A GROUND SURFACE.

METAL HEAD GASKET (0.3)


Name Measure A Thickness
Shimming - Cylinder 67.8 - Head gasket 2.50 2.40 0.4 0.05
0.3 - Base gasket 0.4
Shimming - Cylinder 67.8 - Head gasket 2.40 2.20 0.6 0.05
0.3 - Base gasket 0.6

CHAR - 26
Characteristics

Name Measure A Thickness


Shimming - Cylinder 67.8 - Head gasket 2.20 2.10 0.8 0.05
0.3 - Base gasket 0.8

Products

RECOMMENDED PRODUCTS TABLE


Product Description Specifications
AGIP RACING 4T, SAE 10W-40 Engine oil 10W-40
AGIP GEAR SYNTH SAE 75W-90 Gearbox oil API GL4, GL5
AGIP FORK 7.5W Fork oil
AGIP FILTER OIL Oil for air filter sponge -
AGIP BRAKE 4 Brake fluid FMVSS DOT4+
SPECIAL AGIP PERMANENT fluid Coolant Biodegradable coolant, ready for use,
with "long life" technology and character-
istics (pink). Freezing protection up to
-40. According to CUNA 956-16 stand-
ard.
AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2
bearings and other points needing lubri-
cation
NEUTRAL GREASE OR PETROLEUM Battery poles Neutral grease or petroleum jelly.
JELLY

CHAR - 27
INDEX OF TOPICS

TOOLING TOOL
Tooling

SPECIFIC TOOLS
Stores code Description
020622Y Transmission-side oil seal punch

020565Y Flywheel lock calliper spanner

001467Y013 Calliper to extract 15-mm diameter bear-


ings

001467Y035 Bell for OD 47-mm bearings

020150Y Air heater support

020151Y Air heater

TOOL - 29
Tooling

Stores code Description


020193Y Gauge for oil pressure check

020262Y Crankcase splitting strip

020263Y Sheath for fitting the driven pulley

020287Y Ring to assemble piston on cylinder

020306Y Punch for fitting the valve sealing rings

020329Y Vacuum pump Mity-Vac

TOOL - 30
Tooling

Stores code Description


020331Y Digital multimeter

020357Y 32x35 mm punch

020359Y 42 x 47 mm punch

020360Y Adaptor 52x54 mm

020363Y Crankshaft oil seal punch D 20 mm

020368Y driving pulley lock wrench

TOOL - 31
Tooling

Stores code Description


020375Y 28x30 mm punch

020376Y Adapter handle

020382Y Tool for removing valve cotters fitted with


part 012

020382Y011 adaptor for valve removing tool

020393Y Piston fitting ring

020412Y Clutch oil seal punch D 15 mm

TOOL - 32
Tooling

Stores code Description


020423Y Driven pulley lock wrench

020424Y Punch for fitting driven pulley roller casing

020425Y Punch for flywheel side oil seal

020430Y Tool for fitting the pin snap rings

020434Y Fitting for oil pressure check

020444Y011 adaptor ring

TOOL - 33
Tooling

Stores code Description


020444Y009 46 x 55 wrench

020444Y010 adaptor ring

020442Y Pulley lock wrench

020444Y Tool for fitting/removing the clutch on the


driven pulley

020455Y 10-mm guide for oil seal on water pump


shaft

020456Y 24 mm adaptor

TOOL - 34
Tooling

Stores code Description


020454Y Tool to fit pin snap rings (200 - 250)

020477Y 37-mm Adaptor

020483Y 30 mm guide

020489Y Stud bolt set for hub cover support

TOOL - 35
INDEX OF TOPICS

MAINTENANCE MAIN
Maintenance

Maintenance chart

ROUTINE MAINTENANCE TABLE


I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Check level every 3,000 km
** Replace every 2 years
*** Replace every 4 years

km x 1,000 1 6 12 18 24 30 36 42 48 54 60
Driven pulley roller casing L L L L L
Safety locks I I I I I I
Spark plug I R I R I R I R I R
driving belt I R I R I R I R I R
Throttle control A A A A A A
Brake disc I I I I I I I I I I I
Air filter C C C C C C C C C C
SAS filter C C C C C
Engine oil filter R R R R R R R R R R R
Valve clearance A A A A
Electrical system and battery I I I I I I I I I I I
Braking systems I I I I I I I I I I I
Light circuit I I I I I I I I I I I
Brake control levers L L L L L L
Brake fluid ** I I I I I I I I I I I
Coolant level** I I I I I I I I I I I
Exhaust muffler/ silencer I I I I I
Engine oil* R R R R R R R R R R R
Hub oil R I I I R I I I R I I
Headlight aiming adjustment A A A A A
Brake pads I I I I I I I I I I I
Sliding blocks / Variable speed rollers I R I R I R I R I R
Vehicle test drive I I I I I I I I I I I
Radiator C C C
Idle speed A A A A A A
Wheels/tyres I I I I I I I I I I I
Suspensions I I I I I
Steering I I I I I I
Transmissions L L L L L
Fuel pipes *** I I I I I I I I I I

Spark plug
CAUTION

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.
Check and/or replace the spark plug at the intervals shown in the scheduled maintenance table. To
reach the spark plug:

Remove the central cover of the chassis.


Undo the indicated screw and remove the spark plug inspection cover.

MAIN - 37
Maintenance

Disconnect the tube.


Unscrew the spark plug.

Characteristic
Spark plug electrode gap
0.7 -0.8 mm
Spark plug
NGK CR7EB

To refit, carry out removal operations but in reverse order

Hub oil

Ride a few kilometres until the regular working temperature is reached, then shut off the engine.
NOTE
USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE.

Check

Park the vehicle on firm and level


ground.
Rest the vehicle on its centre stand.
Unscrew and pull out the measuring
cap-dipstick.
Clean the area in contact with oil with
a clean cloth.
Screw the cap-dipstick fully down into
its tube.
Pull out the cap-dipstick again and
read the level the oil reaches on the
dipstick.
The level is correct when it is close to
the first notch above the little round
mark.
Top-up if necessary.
CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE AND THE EX-
HAUST SYSTEM ARE COLD.

TOP-UP

Pour a small quantity of oil through the fill opening and wait about one minute so that the oil
flows evenly into the crankcase.

MAIN - 38
Maintenance

Check the oil level and top up, if required.


Top-up with small quantities of oil, until the recommended level is reached.
At the end of the operation, screw and tighten the cap-dipstick.
NOTE
RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC-
OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND
CAN CAUSE IRRETRIEVABLE DAMAGE

Replacement

Park the vehicle on firm and level ground.


Rest the vehicle on its centre stand.
Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and
cool down.
CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.
Unscrew and pull out the measuring
cap-dipstick.

Place a +300 cm (18.3 cu.in) capacity


container under the drain screw. Un-
screw and remove the drain screw and
let the oil drain off completely.
Screw and tighten the drain screw.
Add oil through the transmission oil fill
opening.
Screw and tighten the measuring cap-
dipstick.
Start the engine and let it run for sev-
eral minutes. Stop the engine and let it
cool down.
Check the transmission oil level.
CAUTION
USED OIL CONTAINS SUBSTANCES THAT ARE HARM-
FUL TO THE ENVIRONMENT. DISPOSE OF USED OIL AC-
CORDING TO THE REGULATIONS IN FORCE.

MAIN - 39
Maintenance

Air filter

Clean and check the air filter following the indications specified in the scheduled maintenance table.
Carry out the maintenance procedures more frequently if the vehicle is used in rainy or dusty areas, or
off road. In this case, the air filter can be partially cleaned after travelling along these kinds of roads.
CAUTION
PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACE-
MENT.
DO NOT START THE ENGINE WITHOUT THE AIR FILTER.
DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FILTERING ELEMENT; THE FUEL SUPPLY
SYSTEM MAY CATCH FIRE POSING A GREAT RISK FOR PEOPLE AND THE VEHICLE ITSELF.
Remove the filter.
Wash the filtering element with clean,
non-flammable or high-volatility sol-
vents, and let it dry properly.
Apply a specific filter oil over all the
surface.
CAUTION
PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE
NOR POSTPONE AIR FILTER REPLACEMENT.
DO NOT START THE ENGINE WITHOUT THE AIR FILTER.
DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FIL-
TERING ELEMENT; THE FUEL SUPPLY SYSTEM MAY
CATCH FIRE POSING A GREAT RISK FOR PEOPLE AND
THE VEHICLE ITSELF.

Check the lower part of the bleed pipes 1 for dirt.

Remove any deposit coming from the filter housing found inside the bleed pipe. Proceed as follows:

Remove the caps 2.


Drain the content in a container; then, send it to a recycling bank.
WARNING

NEVER REUSE A FILTER.


Replace the air filter with a new one of the same type.

Engine oil

MAIN - 40
Maintenance

Replacement

Rest the vehicle on its centre stand.


Shut off the engine and let it cool down,
so that the crankcase oil drains out and
cools off.
Unscrew and pull out the cap-dipstick
1.
Place a container under the filter to col-
lect the engine oil.
NOTE
PARK THE VEHICLE ON SAFE AND LEVEL GROUND.
CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE AND THE EX-
HAUST SYSTEM ARE COLD.

Unscrew and remove the cartridge en-


gine oil filter 4.
Unscrew and remove the oil drainage
plug 3 and then drain all the engine
oil into the collecting container.
Fit a new oil cartridge filter 4 and
take special care to lubricate the filter
sealing O-rings with oil.
Screw and tighten the engine oil drain-
age plug 3.
Add oil through the transmission en-
gine oil fill opening.
Screw and tighten the measuring cap-
dipstick 1.
Start the engine and let it run for sev-
eral minutes.
Stop the engine and let it cool down.
Check the engine oil level.
CAUTION
USED OIL CONTAINS SUBSTANCES THAT ARE HARM-
FUL TO THE ENVIRONMENT. DISPOSE OF USED OIL AC-
CORDING TO THE REGULATIONS IN FORCE.

Check

Park the vehicle on firm and level ground.


Rest the vehicle on its centre stand.

MAIN - 41
Maintenance

CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.
Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down.
NOTE
FAILURE TO FOLLOW THESE OPERATIONS MAY RESULT IN AN INCORRECT READING OF
THE ENGINE OIL LEVEL.
Unscrew and take out the measuring
cap-dipstick 1.
Clean the area in contact with oil with
a clean cloth.
Screw the cap-dipstick 1 fully down
into its tube 2.
Pull out the cap-dipstick again 1 and
read the level the oil reaches on the
dipstick:

MAX = maximum level.


MIN = minimum level.

The level is correct when it is close to


"MAX" level, marked on the measuring
dipstick.
Top up if necessary.
WARNING
DO NOT GO BEYOND THE "MAX" OR BELOW THE "MIN"
LEVEL MARKS TO AVOID SEVERE ENGINE DAMAGE.

ENGINE OIL TOP-UP

Pour a small quantity of oil through the fill opening 2 and wait about one minute so that
the oil flows evenly into the crankcase.
Check the oil leveland top-up,if required.
Top-up with small quantities of oil, until the recommended level is reached.
At the end of the operation, screw and tighten the cap-dipstick 1.
NOTE
RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC-
OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND
CAN CAUSE IRRETRIEVABLE DAMAGE.
NOTE
DO NOT EXCEED THE "MAX" MARK WHEN TOPPING-UP ENGINE OIL.

Cooling system

Level check
CAUTION

MAIN - 42
Maintenance

WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANT
LEVEL.
CAUTION

PARK THE VEHICLE ON SAFE AND LEVEL GROUND.


Shut off the engine and wait until it
cools off.
Undo the indicated screw on both sides
and remove the front case.

Make sure that the liquid level in the


expansion tank is between "MIN" and
"MAX" references.
Otherwise, top-up.

DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO


THE OIL.

TOP-UP

Loosen but do not remove the coolant reservoir cap.


Wait for some seconds so that possible pressure may be purged.
Unscrew and remove the cap
Top up with the recommended product until the liquid approximately reaches the "MAX"
level.
Refit the fuel tank cap.
CAUTION
IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK
REMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT.
Radiator cleaning

Remove the front case.


Wash the radiator with a pressurised water jet.
Blow the radiator with compressed air.
NOTE
IT IS NOT NECESSARY TO REMOVE THE RADIATOR

MAIN - 43
Maintenance

Braking system

The following operations refer to both braking systems.


CAUTION
PURGE THE AIR IN THE SYSTEM IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER,
EXCESSIVE ELASTICITY OR AIR BUBBLES IN THE CIRCUIT.
DO NOT USE OR MIX DIFFERENT SILICON- OR PETROLEUM-BASED COOLANT TYPES.
PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIR-
CUIT.

Level check

Park the vehicle on its centre stand.


Turn the handlebar so that the fluid in
the brake fluid reservoir is parallel to
the MIN reference mark indicated on
the sight glass 1.
Check that the level in the reservoir is
over the MIN reference mark indica-
ted on the sight glass 1.

MIN = minimum level.


If the fluid does not reach at least the MIN ref-
erence mark:
CAUTION
BRAKE LEVEL DECREASES GRADUALLY AS BRAKE
PADS WEAR DOWN.

Check brake pads and disc for wear. If the pads and/or the disc do not need replacing, top-up the
fluid.

Top-up

Remove the front handlebar cover.


Undo and remove the four screws in-
dicated.
CAUTION
RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE
FRONT BRAKE LEVER WHEN THE SCREWS ARE LOOSE
OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COV-
ER HAS BEEN REMOVED. PLACE A CLOTH UNDER THE
BRAKE FLUID RESERVOIR TO PROTECT IT FROM ANY
FLUID LEAKS.

MAIN - 44
Maintenance

Remove the cover and top up the res-


ervoir with the recommended liquid un-
til the correct level is reached
CAUTION
DO NOT SHAKE THE VEHICLE TO AVOID BRAKE FLUID
SPLASHING DURING TOP-UP.
CAUTION
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE
FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS
MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE
BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME
NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.
CAUTION
DO NOT FILL UP THE TANK TO THE MAXIMUM, BUT JUST
OVER THE ''MIN'' LEVEL. TOP-UP TO MAXIMUM LEVEL
MARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE LEV-
EL DECREASES GRADUALLY AS BRAKE PADS WEAR
DOWN. IT IS ADVISABLE NOT TO TOP-UP TO THE MAX
LEVEL MARK WHEN THE BRAKE PADS ARE WORN BE-
CAUSE YOUR RISK SPILLING FLUID WHEN CHANGING
THE BRAKE PADS.

Headlight adjustment

For a quick check of the correct direction of the


front light beams, place the vehicle ten metres
from a vertical wall and make sure the ground is
level.
Turn on the low-beam light, sit on the vehicle and
check that the light beam projected to the wall is a
little below the headlight horizontal straight line
(about 9/10 of the total height).

To adjust the light beam:

Use a screwdriver to act on the corre-


sponding screws 1 on the front
wheel housing.

SCREW it (clockwise) to raise the light beam.


UNSCREW it (anticlockwise) to lower the light
beam.

MAIN - 45
INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS


Electrical system

KEY:
1. Multiple connectors
2. Fuel Level Sensor
3. Instrument panel
4.Thermistor
5.Speed sensor
6. MODE Button
7. Horn
8. Key switch
9. Front stop switch
10. Rear stop switch
11.Light switch
12. Left rear turn indicator
13. Twin tail light/stop light bulb
14. Right rear turn indicator
15. Rear light assembly
16. License plate light
17. Stop light relay
18. Turn indicators switch
19. Start-up relay

ELE SYS - 47
Electrical system

20. Starter motor


21. Main fuses
22. Auxiliary fuses
23. Plug socket
24. Battery
25. HV coil
26. Spark plug
27. Automatic starter
28. CDI Control Unit
29. Connection for oil sensor (USA only)
30. Oil pressure sensor
31. Pick-up
32. Generator
33. Voltage regulator
34. Thermometric switch
35. Fan
36. Glove-box light
37. Glove-box light switch
38. Right front turn indicator
39. - Headlamp tail light
40. High-beam bulb
41. Low-beam bulb
42. Left front turn indicator
43. Complete front headlamp
44. Blinker (USA only)
45.Kit for blinker (USA only)
46. Horn button
47.Start button
48. Engine stop switch

CABLE COLOURS
Ar orange
Az sky blue
B blue
Bi white
G yellow
Gr grey
M brown
N black

ELE SYS - 48
Electrical system

R red
V green
Vi purple
Ro pink

Components arrangement

1. Fan
2. Thermometric switch
Remove the legshield to reach it.

ELE SYS - 49
Electrical system

3. Horn
4. Voltage regulator
Remove the front wheel housing to reach it.

Electric characteristic
No-load recharge voltage
13 15 V at 5000 rpm

5. Battery
6. Fuses
Remove the battery cover on the footrest to reach
them.

7. Start-up relay
8. Stop light relay
Remove the footrest to reach it.

9. Speed sensor
It is placed on the rear wheel.

ELE SYS - 50
Electrical system

10. Magneto flywheel


11. Automatic starter
Remove the tail section to reach connectors.

Electric characteristic
Permanent magnet generator
12V - 180W
Stator winding resistance
0.11 Ohm at 20 C (68 F)
Off-load generated voltage
> 50 V at 5000 RPM
Pick-up winding resistance
10510% Ohm at 20 C (68 F)
Starter resistance
~30 Ohm at 20 C (68 F)

12. Control unit


Remove the tail section to reach it.

13. Fuel Level Sensor


Remove the plastic cover under the saddle to
reach it.

Electric characteristic
Full tank
10010% Ohm
Empty tank
120010% Ohm

ELE SYS - 51
Electrical system

14. Thermistor
Remove the helmet compartment to reach it.

Electric characteristic
Resistance at 100 C (212F)
144 Ohm
Resistance at 80 C (176F)
262 Ohm
Resistance at 60 C (140F)
512 Ohm
Resistance at 40 C (104F)
1090 Ohm

15. HV coil
Remove the rear central cover to reach it.

Electric characteristic
Secondary resistance
290010% Ohm at 20 C (68 F)
Primary resistance
0.210% Ohm at 20 C (68 F)

ELE SYS - 52
Electrical system

Front side

ELE SYS - 53
Electrical system

ELE SYS - 54
Electrical system

KEY
1.Push through the hole
2. Long black clamps (290x4.5)
3.Push through the hole

ELE SYS - 55
Electrical system

KEY
1. Medium black clamps (180x4.5)

ELE SYS - 56
Electrical system

KEY
1. Medium black clamps (180x4.5)

ELE SYS - 57
Electrical system

KEY
1. Long black clamps

ELE SYS - 58
Electrical system

KEY
1.Long black clamps (290x4.5)

ELE SYS - 59
Electrical system

ELE SYS - 60
Electrical system

ELE SYS - 61
Electrical system

KEY
1. Long black clamps (290x4.5)

ELE SYS - 62
Electrical system

ELE SYS - 63
Electrical system

Back side

KEY
1. Medium black clamps (180x4.5)

ELE SYS - 64
Electrical system

KEY
1. Small black clamps (98x2.5)

ELE SYS - 65
Electrical system

KEY
1. Rubber cap
2.Medium black clamps (180x4.5)

ELE SYS - 66
Electrical system

KEY
1. Small black clamps (98x2.5)

ELE SYS - 67
Electrical system

KEY
1. Small black clamps (98x2.5)
2. Cable guide

ELE SYS - 68
Electrical system

KEY
1. Long black clamps (290x4.5)

ELE SYS - 69
Electrical system

KEY
1.Long black clamps (290x4.5)

ELE SYS - 70
Electrical system

KEY
1. Long black clamps (290x4.5)

ELE SYS - 71
Electrical system

KEY
1.Small black clamps (98x2.5)

ELE SYS - 72
Electrical system

KEY
1.Medium black clamps (180x4.5)

ELE SYS - 73
Electrical system

Conceptual diagrams

Ignition

KEY:
8. Key switch
21. Main fuses
22. Auxiliary fuses
24.Battery
25. HV coil
26.Spark plug
28. CDI Control Unit
31. Pick-up
48. Engine stop switch

ELE SYS - 74
Electrical system

Battery recharge and starting

KEY:
8. Key switch
9.Front stop switch
10. Rear stop switch
19. Start-up relay
20. Starter motor
21. Main fuses
22. Auxiliary fuses
24. Battery
32. Generator
33. Voltage regulator
47. Start button
48. Engine stop switch

ELE SYS - 75
Electrical system

Level indicators and enable signals section

KEY:
1. Multiple connectors
2. Fuel Level Sensor
3.Instrument panel
4.Thermistor
5.Speed sensor
8.Key switch
21. Main fuses
22. Auxiliary fuses
24.Battery
29. Connection for oil sensor (USA only)
30.Oil pressure sensor

ELE SYS - 76
Electrical system

Devices and accessories

KEY:
3.Instrument panel
6.MODE Button
7. Horn
8.Key switch
21. Main fuses
22. Auxiliary fuses
23. Plug socket
24. Battery
27.Automatic starter
28. CDI Control Unit
34.Thermometric switch
35.Fan
46. Horn button

ELE SYS - 77
Electrical system

Lights and turn indicators

KEY:
3.Instrument panel
8.Key switch
9.Front stop switch
10. Rear stop switch
11. Light switch
12.Left rear turn indicator
13. Twin tail light/stop light bulb
14. Right rear turn indicator
15.Rear light assembly
16.License plate light
17. Stop light relay
18. Turn indicator switch
21. Main fuses
22. Auxiliary fuses
24.Battery
28.CDI Control Unit
38.Right front turn indicator

ELE SYS - 78
Electrical system

39. -Front headlamp tail light


40. High-beam bulb
41. Low-beam bulb
42. Left front turn indicator
43.Complete front headlamp
44. Blinker (USA only)
45. Kit for blinker (USA only)
48.Engine stop switch

Checks and inspections

Ignition circuit

No spark plug
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
Check spark plug for correct conditions, clean it
and remove deposits. Replace it, if necessary.

Pick-Up Check

With engine off disconnect the control


unit connector.
Measure the resistance present be-
tween terminals No. 6 (Blue-Yellow ca-
ble) and No. 8 (Blue cable).
If the value measured is incorrect, re-
peat the check directly on the compo-
nent.

ELE SYS - 79
Electrical system

Disconnect the Pick-Up connector and


measure the resistance between the
pin corresponding to the Blue-Yellow
cable of the wiring and the ground con-
nection on the engine.
If the value measured is correct, check
wiring continuity.

Electric characteristic
Pick-up winding resistance
10510% Ohm at 20 C (68 F)

Coil primary check:

Disconnect the connector of the control


unit.
Measure the resistance present be-
tween terminals No. 3 (White-Purple
cable) and No. 8 (Blue cable).
If the measured value is incorrect, re-
peat the check between the positive
and negative terminals of the coil.
If a correct value is measured, check
wiring continuity.

Electric characteristic
Primary resistance
0.210% Ohm at 20 C (68 F)

Coil secondary check

Disconnect the spark plug cap from the


coil cable and measure the resistance
between the cable end and the coil
green negative terminal.

Electric characteristic
Secondary resistance
290010% Ohm at 20 C (68 F)

Battery recharge circuit


With engine running at high revs, measure the voltage present at the battery poles.

Electric characteristic
No-load recharge voltage

ELE SYS - 80
Electrical system

13 15 V at 5000 rpm

Stator check

Checking the stator winding


WARNING
THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Remove the front wheel housing.
2) Disconnect the voltage regulator connector.
3) Measure the resistance between each of the
yellow terminals and the other two.

Electric characteristic
Stator winding resistance
0.11 Ohm at 20 C (68 F)

4) Check that there is insulation between the each


yellow cable and the earth.
5) If incorrect values are detected, repeat the
check directly on the stator and control cable har-
nesses if necessary.

Recharge system voltage check

Connect the ammeter induction clamp


to the voltage regulator positive termi-
nal (Red-Orange).
Measure the battery voltage and turn-
ing on the vehicle lights, with engine
off, wait for the voltage to set at about
12 V.
Start the engine and measure the cur-
rent generated by the system with
lights on and a high running engine.

Characteristic
Generated current:
6A at 6000 rpm

ELE SYS - 81
Electrical system

Start up system check

KEY:
1. Key switch
2.Front stop switch
3.Rear stop switch
4. Start button
5.Engine stop switch
6. Start-up relay
7. Starter motor
8.Battery
9. Main fuses
10. Auxiliary fuses
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.

ELE SYS - 82
Electrical system

1) Check fuses No. 1 and 4.


2) Check key switch and engine stop switch con-
tacts.
3) Check stop switches and start button contacts.
4) Try to start up and check for voltage between
the Yellow-Red cable and the Blue cable of the
start-up relay (see figure).
5) If voltage is not detected, check cable harness
continuity.

6) Check the start-up relay.


7) Check the integrity and the connections of the
Red cable that connects the battery to the start-up
relay.
8) Repeat the check with the Red cable that con-
nects the start-up relay and the starter motor (see
figure).

Horn control

KEY:
1. Horn button

ELE SYS - 83
Electrical system

2. Key switch
3. Horn
4.Battery
5.Main fuses
6.Auxiliary fuses
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
1) Check fuses No. 1 and 3.
2) Check key switch and horn button contacts.
3) With the key switch set to ON, check for volt-
age between the Green cable of the horn button
and ground. If voltage is not detected, check cable
harness continuity.
4) Check the integrity and the connections of the
Grey cable of the horn and the horn ground lead
(Blue cable).

Choke Inspection

KEY:
1.CDI Control Unit

ELE SYS - 84
Electrical system

2. Key switch
3.Main fuses
4.Battery
5.Auxiliary fuses
6.Automatic starter
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
1) Keep the connector connected to the system
and check for voltage between both terminals of
the starter when the engine is on.
2) If no voltage is detected, check the continuity of
the Green-Red cable with fuse No. 4 and that of
the Green-Black cable with the control unit (pin 7).

Electric characteristic
Starter resistance
~30 Ohm at 20 C (68 F)

Turn signals system check

KEY:
1. Instrument panel

ELE SYS - 85
Electrical system

2.Turn indicators switch


3. Left rear turn indicator
4.Right rear turn indicator
5.CDI Control Unit
6.Right front turn indicator
7.Left front turn indicator
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
1) Check that bulbs and their ground connection are in working conditions (Blue cables).
2) Check the continuity of the Blue-Black cable connecting the control unit (pin 1) and the turn indicator
switch.
3) Check the contacts of the turn indicator switch.
4) Check the integrity and the connections of the bulbs cable harnesses (Sky blue and Red cables) to
the turn indicator switch.

level indicators

KEY:
1.Fuel Level Sensor
2.Instrument panel
CAUTION

ELE SYS - 86
Electrical system

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
1) Measure the resistance in the fuel level sensor
ends in the different conditions.
2) If the resistance values are correct, but the in-
dication on the instrument panel is incorrect, check
the integrity and the connections of the cable har-
nesses (Brown cable with pin 7 of the instrument
panel connector and Grey-Green cable with pin 12
of the instrument panel connector.)

Electric characteristic
Full tank
10010% Ohm
Empty tank
120010% Ohm

Lights list

KEY:
1.Instrument panel
2. Light switch

ELE SYS - 87
Electrical system

3.Key switch
4.Twin tail light/stop light bulb
5.License plate light
6. Battery
7. Main fuses
8.Auxiliary fuses
9. High-beam bulb
10. Front headlamp tail lights
11.Low-beam bulb

BULBS/WARNING LIGHTS
Specification Desc./Quantity
1 High-/low-beam bulb 12 V - 55 W - H7
2 Tail light bulb 12V - 5W
3 Front turn indicator bulbs 12 V - 10 W (Amber)
4 Rear turn indicator bulbs 12 V - 10 W (White)
5 Rear tail light /stop light bulb 12 V - 5/21 W (Red)
6 License plate light bulb 12V - 5W
7 Instrument panel lighting bulb LED
8 Turn indicator warning light LED
9 High-beam warning light LED
10 Low fuel warning light LED
11 Engine oil pressure warning light LED
12 High coolant temperature gauge warning light LED
CAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-
CONNECTED.
Tail lights line check
1) Check that bulbs and their ground connection are in working conditions (Blue cables).
2) Check fuses No. 1 and 3.
3) Check key switch contacts.
4) Check the integrity and the connections of the bulbs cable harnesses (Green cables) with fuse No.
3.
High-beam/low-beam lights line check
1) Check that bulbs and their ground connection are in working conditions (Blue cables).
2) Check fuses No. 1 and 3.
3) Check key switch and light switch contacts.
4) With the key switch set to ON, check for voltage between the light switch Green cables and ground.
If voltage is not detected, check cable harness continuity.
5) Check that the connections between bulb cable harnesses (White cable and Black cable) and the
light switch are in good conditions.

ELE SYS - 88
Electrical system

Fuses
CAUTION

DO NOT REPAIR FAULTY FUSES.


NEVER USE FUSES OTHER THAN THE ONES SPECIFIED.
A SHORT CIRCUIT MAY DAMAGE THE ELECTRICAL SYS-
TEM OR EVEN CAUSE A FIRE.
NOTE
IF THE SPARE FUSE IS USED, REPLACE WITH ONE OF
THE SAME TYPE IN THE CORRESPONDING FITTING.

FUSE DISTRIBUTION
Specification Desc./Quantity
1 Fuse No. 1 Capacity: 20A
Protected circuits: Key switch, instrument panel, fan
and recharge circuit.
2 Fuse No. 2 Capacity: 15 A
Protected circuits: From battery to plug socket.
3 Fuse No. 3 Capacity: 15 A
Protected circuits: From key switch to tail lights, stop
lights, high-beam light, low-beam light, horn and instru-
ment panel.
4 Fuse No. 4 Capacity: 7.5A
Protected circuits: From key switch to automatic start-
er, ignition and start-up circuit.

Dashboard

KEY
1. Blue high-beam warning light
2. Green turn indicators warning light
3. Fuel gauge
4. Orange low fuel warning light

ELE SYS - 89
Electrical system

5. Speedometer
6. Coolant high temperature warning light
7. Coolant temperature gauge
8. Red oil pressure warning light.
9. ABS warning light (Activated on ABS versions only)
10. Multifunction indicator: total odometer (ODO) / two trip odometers (ODO I - ODO II) / battery voltage
11. Warning light not active
12. Digital clock

Km or miles selection
Quickly press the MODE button, select the battery voltage measurement function. Hold down the MODE
button for more than 10 seconds to change from km to mile reading for the odometer.
For the first 5 seconds the button is held down, there will be no instrument panel indication, but for the
next 5 seconds, the legend of the unit of measurement (km or miles) currently in use will flash at a
frequency of 1 Hz. If the button is released before 10 seconds elapse, the unit of measurement does
not vary.

Data check function


WARNING
THE SERVICE WARNING LIGHT IS NOT ACTIVE. WHEN THE KEY IS INSERTED, THE SERVICE
COUPONS ICON SHALL BE ON FOR TWO SECONDS ONLY AFTER REACHING 50,000 KM. CAR-
RY OUT THE RESET SERVICE TO ELIMINATE THE SERVICE COUPONS ICON IGNITION.
RESET
Hold the MODE button down.

Turn the key to ''ON'' and wait 10 seconds.


During this operation the service icon flashes at a
1 Hz frequency.

ELE SYS - 90
Electrical system

Sealed battery

Commissioning sealed batteries (without maintenance)


In case the vehicle fits a sealed battery, the maintenance is limited to the loading state and to an eventual
recharge. These operations should be carried out before delivering the vehicle, and on a six-month
basis while the vehicle is stored in open circuit. Besides upon pre-delivery, it is therefore necessary to
check the battery charge and recharge it, if required, before storing the scooter and afterwards every
6 months.
INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE

1. Voltage check
2. Before installing the battery on the vehicle, check the open circuit voltage with a standard
tester.
If voltage is over 12.60V, the battery can be installed without any refresh.
If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
3. Constant-voltage battery charge mode
4. Constant-voltage charge equal to 14.4014.70V
Initial charge current equal to 0.30.5 of the battery rated capacity
Charge time:
10 to 12 h recommended Minimum 6 h Maximum 24 h
5. Constant-current battery charge mode
6. Charge current equal to 1/10 of the battery rated capacity

Dry-charge battery

Commissioning dry charge battery (with maintenance)


WARNING

BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS


SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF IT ACCIDEN-
TALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER
FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
MILK FOLLOWED BY MAGNESIUM MILK, BEATEN EGG OR VEGETABLE OIL. SEEK IMMEDIATE
MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN

ELE SYS - 91
Electrical system

Remove the short closed tube and the


caps, then pour sulphuric acid into the
cells, using the type specified for bat-
teries, with a specific gravity of 1.26,
corresponding to 30 B, at a minimum
temperature of 15C until the upper
level is reached.
Leave to rest for at least 2 hours, then
restore the level with sulphuric acid.
Within the following 24 hours, recharge
with the specific battery charger at an
intensity of about 1/10 of the battery
nominal capacity and until the acid
density is about 1.27, corresponding to
31 B, and these values are stabi-
lised.
Once the charge is complete, level the
acid (by adding distilled water). Close
and clean carefully.
Once the above operations have been
performed, install the battery on the ve-
hicle ensuring that it is connected prop-
erly.
1 Hold the tube upright
2 Inspect visually
3 The float must be freed
Electrolyte level check
The electrolyte level must be checked frequently and must reach the upper level. Only use distilled
water to restore this level. If it is necessary to add water too frequently, check the vehicle electrical
system: the battery works overcharged and is subject to quick wear.
Charge status check
After topping-up the electrolyte level, check its density using an appropriate densitometer.
With the battery charged, a density of 3032 B, corresponding to a specific weight of 1.261.28, must
be at a minimum temperature of 15 C.
A density reading below 20 B indicates that the battery is completely flat and must therefore be
recharged.
If the vehicle is not be used for a certain time (1 month or more), the battery needs to be recharged
periodically.

ELE SYS - 92
Electrical system

The battery runs down completely in about three months. Should the battery be fitted on a vehicle, be
careful not to invert the connections, keeping in mind that the ( black) ground wire marked (-) is con-
nected to the - negative terminal while the other two red wires marked (+) are connected to the +
positive terminal.

Battery recharge
WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP NAKED
FLAMES OR SPARKS AWAY FROM THE BATTERY WHILE CHARGING.
First detach the negative terminal before removing the battery from the vehicle.
Normal bench charging must be performed using the special battery charger, setting the battery charge
selector to the type of battery that requires recharging (that is, at a current equal to 1/10 of the battery
rated capacity). Connections to the power supply source must be implemented by connecting corre-
sponding poles (+ to + and - to -).

The battery should always be kept clean, especially its top side, and the terminals should be coated
with petroleum jelly.
CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CAUTION

ORDINARY DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL TO THE BAT-
TERY. CONSEQUENTLY, ONLY USE DISTILLED WATER.
CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.


INADEQUATE CHARGING OF THE BATTERY BEFORE BEING PUT INTO OPERATION SHORT-
ENS BATTERY LIFE.

ELE SYS - 93
Electrical system

Connectors

ENGINE CONNECTOR
1. Stator phase (Yellow)
2.Not connected
3.Stator phase (Yellow)
4. Oil pressure sensor (Purple)
5.Stator phase (Yellow)
6.Pick-up (Blue-Yellow)

VOLTAGE REGULATOR CONNECTOR


1. Magneto flywheel (Yellow)
2.Magneto flywheel (Yellow)
3.Magneto flywheel (Yellow)
4. Battery positive (Red-Orange)
5. Not connected
6. Ground (Blue)

ECU

1.Turn indicators switch (Blue-Black)


2.Not connected
3.HV coil (White-Purple)
4.Not connected
5.Live supply (White-Black)
6.Pick-up (Blue-Yellow)
7.Automatic starter (Green-Black)
8.Ground (Blue)

ELE SYS - 94
Electrical system

Dashboard

1.Oil pressure sensor (Purple)


2. MODE Button (Pink)
3. Left turn indicator warning light (Sky Blue)
4. Right turn indicator warning light (Red)
5.High-beam warning light (White)
6. Not connected
7. Fuel level sensor (Brown)
8. Speed sensor negative (Yellow-White)
9. Not connected
10. Speed sensor positive (Orange-Black)
11. Not connected
12. Fuel level sensor (Yellow-Green)
13.Thermistor (White-Blue)
14. Speed sensor signal (Blue-Orange)
15. Not connected
16. Ground (Blue)
17. Ground (Blue)
18. Not connected
19. Live supply (Green)
20. Battery-powered (Red-Orange)

ELE SYS - 95
INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE


Engine from vehicle

Exhaust assy. Removal


CAUTION
ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF.
Remove the rear central cover.
Undo and remove the two fixing nuts of
the exhaust manifold

Undo and remove the three fixing


screws of the exhaust silencer.
Remove the exhaust system.

Silencer removal

Rest the vehicle on its centre stand.


Loosen the clamp (1) fixing the exhaust
silencer to the manifold.
Undo and remove the three fixing
screws (2).
Remove exhaust silencer.

Removal of the engine from the vehicle

Remove the saddle.


Remove the luggage rack.
Remove the side fairings.
Remove the tail section.
Remove the helmet compartment.

ENG VE - 97
Engine from vehicle

Remove the rear brake calliper and release the


pipes from the engine by unscrewing the indicated
screw.

Remove the speed sensor by undoing


the fixing screw.

Remove the spark plug tube.

Remove the pipe connecting the radi-


ator to the water pump and empty the
system.

ENG VE - 98
Engine from vehicle

Remove the fuel inlet and delivery


pipes from the fuel pump.

Remove the fuel manifold from the car-


burettor.

Remove the coolant temperature sen-


sor connector.

Remove the starter motor power sup-


ply cable and the ground lead to re-
lease cable harnesses.

ENG VE - 99
Engine from vehicle

Remove the automatic starter connec-


tor and the generator connector.

Remove the throttle grip transmission


and release it.

Loosen the swinging arm fixing nut in


the engine.

Slide off the pin and remove the engine


from the vehicle.

When refitting the engine onto the scooter, carry out the removal operations but in reverse
order and respect the tightening torques shown in the Specifications Chapter.
Check the engine oil level and, if necessary, top it up with the recommended type.
Fill up and bleed the cooling circuit.
Check the functioning of the accelerator and the electrical devices.
CAUTION

ENG VE - 100
Engine from vehicle

PAY SPECIAL ATTENTION WHEN POSITIONING THE THROTTLE CONTROL TRANSMISSION


PROPERLY.

ENG VE - 101
INDEX OF TOPICS

ENGINE ENG
Engine

This section describes the operations to be carried out on the engine and the tools required.

Automatic transmission

Transmission cover

- To remove the transmission cover, it is necessary to remove the plastic cover first by inserting a
screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven
pulley shaft nut and washer.

Specific tooling
020423Y Driven pulley lock wrench

- Pull out the cap/dipstick from the engine oil filling tube.
- Remove the 10 screws.
- Now remove the transmission cover.
If this operation is carried out directly on the vehicle, remove the cooling air supply sleeve of the trans-
mission housing.

ENG - 103
Engine

Air duct

125 VERSION

Remove the 4 screws and the small casing.

200 VERSION

- Remove the 5 screws on the two different levels, as well as the small casing

ENG - 104
Engine

Air duct filter

To remove the intake throat on the transmission


cover, just remove the 2 fixing screws indicated in
the figure.

Removing the driven pulley shaft bearing

- Remove the Seeger ring from the inside of the


cover.
- Remove the bearing from the crankcase by
means of:

Specific tooling
020376Y Adapter handle
020375Y 28 x 30 mm adaptor
020412Y 15 mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase internal side so as not


to damage the coated surface.
- Insert the bearing in its housing.
- Refit the Seeger ring.
CAUTION
REST THE COVER ON A SUITABLE SURFACE TO AVOID
DAMAGING THE COVER COAT.
NOTE
ALWAYS REPLACE THE BEARING WITH A NEW ONE AT
EVERY REFIT

Specific tooling
020376Y Adapter handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide

Baffle roller

Removal

Belt support roller (only 200 cc version)

ENG - 105
Engine

- Check that the roller shows no signs of abnormal wear and that it rotates freely.
- Remove the special fixing screw and the roller with the bearing.

Refitting
- Heat up the roller and insert the bearing by using the specific punch:
Specific tools:

Specific tooling
020455Y 10 mm guide

ENG - 106
Engine

- Refit the roller with the special screw.


- Tighten to the specified torque.
- Refit the intake throat with the O-Ring, the sealing gasket for the sump and the closing casing for the
fan.

Locking torques (N*m)


Anti-vibration roller 12 16

Removing the driven pulley


- Remove the spacer, the clutch bell and the whole
driven pulley assembly.
NOTE
THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE
DRIVING PULLEY IS MOUNTED.

Inspecting the clutch drum


Checking the bell working surface eccentricity
- Fit the bell on a driven pulley shaft with 2 bearings (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to check the crankshaft alignment.

- Make sure that the clutch bell is not worn or damaged.


- Measure the clutch bell inside diameter.

Characteristic

ENG - 107
Engine

Clutch bell max. value


Max. value: 134.5 mm
Clutch bell standard value
Standard value: 134 134.2 mm

Inspecting the clutch

- Check the thickness of the clutch mass friction material.


- The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER.
DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING.
CAUTION
DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID VARIATION IN THE RETURN SPRING
LOAD.
Characteristic
Check minimum thickness
1 mm

ENG - 108
Engine

Removing the clutch

Removing the clutch (125cc H2O)


- Prepare the specific tool to compress the driven pulley spring with the medium-length pins in position
F screwed from the tool inner side.
- Insert the adaptor ring No. 8 in the pins.
- Fit the driven pulley unit on the tool by inserting the nail heads in the adaptor ring.
- Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the
clutch nut.
- With the specific 46x55 wrench, component No. 9, remove the clutch fixing nut.
- Disassemble the driven pulley into its components (Clutch, fan and spring with plastic fitting).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST TOUCH
THE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.
Specific tooling
020444Y009 46 x 55 wrench
020444Y010 adaptor ring

ENG - 109
Engine

- Prepare the specific tool to compress the driven pulley spring with the medium-length pins in position
C screwed from the tool inner side.
- Insert the adaptor ring No.11 with the chamfering facing the tool inner side.
- Fit the driven pulley unit on the tool by inserting the three pins in the ventilation holes in the ground
holder support.
- Make sure that the clutch is perfectly inserted into the adapter ring before carrying out the clutch nut
locking/release operations.
- With the specific 46x55 wrench, component No. 9, remove the clutch fixing nut.
- Disassemble the driven pulley into its components (Clutch and spring with plastic fitting).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST TOUCH
THE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.
Specific tooling
020444Y009 46 x 55 wrench
020444Y011 adaptor ring

ENG - 110
Engine

Pin retaining collar

- Simultaneously turn and pull the collar manually to remove it.


NOTE
USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY.
NOTE
BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGING THE O-
RING SEAL.

ENG - 111
Engine

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noise; otherwise, replace it.
- Remove the snap ring using two flat blade screwdrivers.
- Place pulley bushing on the threaded side adequately on a wood support.
- Using a hammer and pin, knock the ball bearing out as shown in the figure.

- Properly support the pulley by means of the specific bell shown in figure.

Specific tooling
001467Y035 Bell for 47-mm outside diameter bearings

ENG - 112
Engine

- Remove the roller bearing using the modular punch.

Specific tooling
020376Y Adapter handle
020456Y 24 mm adaptor
020363Y 20 mm guide

Inspecting the driven fixed half-pulley

- Measure the outside diameter of the pulley bushing.


- Check the contact surface with the belt to make sure there are no signs of abnormal wear.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.

Characteristic
Half-pulley minimum diameter
Minimum diameter allowed: 40.96 mm
Half-pulley standard diameter
Standard diameter: 40.985 mm
Wear limit
0.3 mm

ENG - 113
Engine

Inspecting the driven sliding half-pulley

Remove the belt and slide off the movable half-pulley with the relative bushing, taking care
the free rollers fitted to it do not come out.
Remove the rollers support plate with the relative guide sliders.

Remove the 2 inner sealing rings and


the 2 O-rings.
Measure the inside diameter of the
movable half-pulley bushing.

Characteristic
Moving driven half-pulley max. diameter
Max. diameter allowed 41.08 mm
Movable driven half-pulley standard diameter

ENG - 114
Engine

Standard diameter: 41.000 41.035 mm

Refitting the driven half-pulley bearing

- Place pulley bushing on the threaded side adequately on a wood support.


- Assemble a new roller casing as shown in the figure.
- To fit the new ball bearing, follow the example in the picture using the specific modular punch.
- Assemble the Seeger ring
WARNING
NOTE
FIT THE BALL BEARING SO THAT THE SHIELD IS VISIBLE
Specific tooling
020376Y Adapter handle
020375Y 28 x 30 mm adaptor
020424Y Punch for fitting driven pulley roller casing

ENG - 115
Engine

Refitting the driven pulley

Driven pulley assembly


- Insert the new oil seals and O-rings on the mov-
able half-pulley.
- Lightly grease the O-rings (A) shown in the figure.
- Fit the half-pulley on the bushing with the specific
tool
Check that the pins are not worn and proceed to
refit them in the relative hollows.--
- Refit the torque server closing collar.
- Using a curved-spout grease gun, lubricate the
driven pulley assembly with approximately 6
grams of grease. Apply the grease through one of
the holes in the bushing until grease comes out
through the hole on the opposite side. This proce-
dure is necessary to prevent the presence of
grease beyond the O-rings.
NOTE
THE TORQUE SERVER CAN BE GREASED WITH BEAR-
INGS FITTED OR WHEN THEY ARE BEING REPLACED; IT
MAY BE EASIER TO GREASE TORQUE SERVER WHEN
THE BEARINGS ARE BEING SERVICED.

Specific tooling
020263Y Sheath for fitting the driven pulley
Recommended products
AGIP GREASE SM 2 Grease for C-ring of the
tone wheel
Soap-based lithium grease with NLGI 2 molybde-
num disulphide; ISO-L-XBCHB2, DIN KF2K-20

- Insert the new oil seals and O-rings on the movable half-pulley.
- Lightly grease the O-rings A shown in the figure.

ENG - 116
Engine

Inspecting the clutch spring

- Measure the length of the movable driven half-


pulley spring, when unloaded.

Characteristic
Standard length (125)
106 mm
limit after use (125)
101 mm
Standard length (200)
123 mm
Limit after use (200)
118 mm

Refitting the clutch

125 VERSION

Support the specific tool to compress the driven pulley spring with the control screw in ver-
tical axis.
Prepare the tool with the medium-length screws in position F, screwed from the inside.
Insert the adaptor ring No. 8 in the pins.
Preassemble the cooling fan to the clutch so that keying faces are aligned and the 3 heads
of the mass fulcrum pins A are fully visible.
Insert the clutch on the adaptor ring.
Lubricate the end of the spring that abuts against the torque server closing collar.
Insert the spring with the relative plastic support in contact with the clutch.

ENG - 117
Engine

Insert the driving belt in the pulley assembly observing the direction of rotation.
Insert the pulley assembly and the belt in the tool.
Preload the spring slightly.
Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to
tighten the clutch nut.
Place the tool in the vice with the control screw in horizontal axis.
Preload the spring fully.
Screw the clutch lock-nut and, with the specific 46x55 wrench, tighten it to the prescribed
torque.
Loosen the tool clamp and insert the belt observing the direction of rotation.
Lock again the driven pulley using the specific tool.
Preload the clutch return spring by turning and pulling alternately until maximum opening of
pulleys is reached and place the belt in the minimum diameter rolling position.
Remove the driven pulley / belt assembly from the tool.
NOTE
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE
SHOULD BE MOUNTED CONTACTING THE CLUTCH.
NOTE
WHEN PRELOADING THE SPRING, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING
STOP AND THE BUSHING THREADING.
Specific tooling
020444Y011 adaptor ring
020444Y009 46 x 55 wrench
Locking torques (N*m)
Clutch assembly nut on driven pulley 55 60

ENG - 118
Engine

200 VERSION

ENG - 119
Engine

Support the specific tool to compress


the driven pulley spring with the control
screw in vertical axis.
Prepare the tool with the medium-
length screws in position C, screwed
from the inside.
Insert the adaptor ring No. 11 with the
chamfering facing upwards.
Insert the clutch on the adaptor ring.
Lubricate the end of the spring that
abuts against the torque server closing
collar.
Insert the spring with the relative plas-
tic support in contact with the clutch.
Insert the driving belt in the pulley as-
sembly observing to direction of rota-
tion.
Insert the pulley assembly and the belt
in the tool.
Preload the spring slightly.
Make sure that the clutch is perfectly
inserted into the adapter ring before
proceeding to tighten the clutch nut.
Place the tool in the vice with the con-
trol screw in horizontal axis.
Preload the spring fully.
Screw the clutch lock-nut and, with the
specific 46x55 wrench, tighten it to the
prescribed torque.
Loosen the tool clamp and insert the
belt observing the direction of rotation.
Lock again the driven pulley using the
specific tool.
Preload the clutch return spring by
turning and pulling alternately and
place the belt in the smaller diameter
rolling position.

ENG - 120
Engine

Remove the driven pulley / belt assem-


bly from the tool.
NOTE
WHEN PRELOADING THE SPRING, BE CAREFUL NOT TO
DAMAGE THE PLASTIC SPRING STOP AND THE BUSH-
ING THREADING.
NOTE
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED CONTACTING THE CLUTCH.

Specific tooling
020444Y Tool for fitting/removing the clutch on
the driven pulley
020444Y011 adaptor ring
020444Y009 46 x 55 wrench
Locking torques (N*m)
Clutch assembly lock-nut on driven pulley 55
60 Nm

Refitting the driven pulley


- Refit the clutch bell and the spacer.

Drive-belt
During the wear check indicated in the scheduled
maintenance, it is recommended to check that the
rim bottom of the toothing does not show signs of
incisions or cracks A. If it does, change the belt.

Removing the driving pulley


125 VERSION

ENG - 121
Engine

With the specific tool, remove the nut with the Belleville washer incorporated, the drive in
common with kick-starter versions and the steel washer.
Remove the fixed driving half-pulley.
Remove the steel washer of bushing separation.

Specific tooling
020368Y driving pulley lock wrench

200 VERSION

Insert the specific tool in the internal slots to remove the nut with the built-in Belleville washer.

Specific tooling
020442Y Pulley lock wrench

Remove the start-up crown unit with the torque limiter.


Remove the fixed driving half-pulley with the O-ring and the steel washer in contact with the
bushing.

ENG - 122
Engine

Remove the belt and slide off the movable half-pulley with the relative bushing, taking care
the free rollers fitted to it do not come out.
Remove the rollers support plate with the relative guide sliders.

Check that the internal bushing shown


in the figure is not abnormally worn and
measure its inside diameter.
Measure the outside diameter of the
pulley sliding bushing shown in the fig-
ure.
Check that the rollers are not damaged
or worn.
Check that the guide sliders for the roll-
er contrast plate are not worn.

ENG - 123
Engine

Check that the roller housings or the


surfaces in contact with the belt on both
half-pulleys are not worn.
Check that fixed driving pulley does not
show signs of abnormal wear on the
grooved edge and on the surface in
contact with the belt.
Check that the O-Ring is not deformed.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic
roller (200): Minimum diameter admitted
20 mm
roller (125): Minimum diameter admitted
18.5 mm
sliding bushing: Minimum diameter admitted
25.95 mm
movable driving half-pulley bushing: Max. di-
ameter admitted
26.12 mm
roller (200): Standard Diameter
20.5 20.7 mm
roller (125): Standard Diameter
18.9 19.1 mm
sliding bushing: Standard Diameter
25.959 25.98 mm
movable driving half-pulley bushing: Standard
Diameter
26.000 26.021 mm

Refitting the driving pulley

125 VERSION

Refit the removed Bendix correctly on its seat.

ENG - 124
Engine

Refit the assembly components (inner shim washer, fixed half-pulley, outer shim washer,
drive,and nut), apply Loctite 243 "Super fast" threadlock on the thread and screw the nut to
the prescribed locking torque.
Prevent half-pulley rotation by using the stop wrench specific tool..
Turn the engine manually to obtain the minimum belt tension.
CAUTION
WHEN ASSEMBLING THE FIXED DRIVING HALF-PULLEY, THE BELT MUST BE TOTALLY FREE
SO THAT THE PULLEY IS NOT INCORRECTLY TAUTENED.
Specific tooling
020368Y driving pulley lock wrench

Locking torques (N*m)


Driving pulley nut 75 83

200 VERSION

Preassemble the movable half-pulley


with the roller contrast plate by placing
the rollers in their housings with the
larger support surface in contact with
the pulley according to the direction of
rotation.
Check that the roller contact plate does
not show flaws or is damaged on the
grooved edge.
Fit the entire bushing assembly on the
crankshaft.
Fit the driven pulley/Clutch/belt assem-
bly to the engine.

ENG - 125
Engine

ENG - 126
Engine

Refitting the transmission cover


- Check there are 2 centring dowels and that the sealing gasket for the oil sump has been adequately
fitted on the transmission cover.
- Replace the cover by tightening the 10 screws to the prescribed torque.
- Refit the oil filling cap dipstick.
- Refit the steel washer and the driven pulley nut.
- Tighten the nut to the specified torque using the lock wrench and the torque wrench tools.
- Refit the plastic cover.

Specific tooling
020423Y Driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 13 Driven pulley shaft nut 54 60

End gear

Removing the hub cover


- Empty the rear hub through the oil drainage plug.

ENG - 127
Engine

- Remove the 7 flanged screws indicated in the figure.


- Remove the hub cover and the relevant gasket.

Removing the wheel axle

- Remove the wheel axle with gear.


- Remove the intermediate gear.

Removing the hub bearings

- Check the status of the bearings being examined (wear, clearance and noise). If any fault is detected,
proceed as follows.
- Use the specific extractor to remove the three 15 mm bearings (2 on the crankcase and 1 on the hub
cover)

Specific tooling
001467Y013 Calliper to extract 15-mm diameter bearings

ENG - 128
Engine

Removing the wheel axle bearings

- Remove the Seeger ring from the outside of the hub cover.
- Support the hub cover and expel the bearing.
Remove the oil seal as shown in the figure by using the specific tools.

Specific tooling
020376Y Adapter handle
020477Y 37-mm Adaptor
020483Y 30 mm guide
020359Y 42 x 47-mm adaptor
020489Y Stud bolt set for hub cover support

ENG - 129
Engine

Removing the driven pulley shaft bearing

- Should the driven pulley shaft, its bearing and oil guard be removed, take out the transmission cover
and the clutch assembly as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver; working from inside the bearing and being careful not to
damage the housing, make it come out on the belt transmission side.
- Remove the Seeger ring indicated in the figure
- Remove the driven pulley shaft bearing using the modular punch.

Specific tooling
020376Y Adapter handle
020375Y 28 x 30 mm adaptor
020363Y 20 mm guide

ENG - 130
Engine

Inspecting the hub shaft

- Check the three shafts for wear or distortions on


the toothed surfaces, on the bearing housings and
the oil seal positions.
- In faults are found, replace the damaged parts.

Inspecting the hub cover

- Check that the coupling surfaces are not dented or distorted.


- Check the bearing capacity.
- In case of faults, replace the damaged parts.

ENG - 131
Engine

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.


- Warm the cover crankcase with the specific heat gun.
- Fit the wheel shaft bearing with a modular punch as shown in the figure.
- Fit the Seeger ring.
- Fit the oil guard with its sealing lip facing the hub internal side and place it flush with the internal surface
using the specific tool used on the 52-mm side .
The 52-mm side of the adaptor should face the bearing.

Specific tooling
020376Y Adapter handle
020360Y 52 x 55-mm adaptor
020483Y 30 mm guide

ENG - 132
Engine

Refitting the hub cover bearings

- To fit the hub box bearings, the engine crankcase and the cover should be heated with the specific
heat gun.
- The three 15-mm bearings must be fitted using the appropriate tools:
The 42-mm side of the adaptor should face the bearing.
- Refit the driven pulley shaft bearing with a modular punch as shown in the figure.
- Refit the Seeger ring with the opening opposite to the bearing and the new oil guard levelled with the
crankcase on the pulley side.
NOTE
USE THE STUD BOLT KIT TO SUPPORT THE COVER ADEQUATELY WHEN FITTING THE BEAR-
ING ON THE COVER.
NOTE
IF A BEARING WITH AN ASYMMETRICAL BALL RETENTION CAGE IS USED, PLACE IT SO THAT
THE BALLS ARE VISIBLE FROM THE HUB INTERNAL SIDE.
NOTE
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, THE CRANKCASE SHOULD, AS
FAR AS POSSIBLE, BE SUPPORTED ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIV-
EN VERTICALLY.
Specific tooling
020150Y Air heater support
020151Y Air heater
020412Y 15 mm guide
020376Y Adapter handle
020359Y 42 x 47-mm adaptor
020363Y 20 mm guide

ENG - 133
Engine

Refitting the hub bearings

- Assemble the 3 shafts in the engine crankcase as shown in the figure.

ENG - 134
Engine

Refitting the ub cover

- Fit a new gasket together with the centring dowels.


- Seal the gasket of the breather pipe using black silicone sealant.
- Fit the cover making sure the breather pipe is in the correct position.
- Position the 3 shorter screw, easily recognisable by its different colour, as shown in the figure.
- Fasten the breather pipe support bracket with the lower short screw.
- Fit the remaining 4 screws and tighten the 7 screws to the prescribed torque.

Locking torques (N*m)


Rear hub cover screws 24 27

ENG - 135
Engine

Flywheel cover

Removing the hub cover

- Remove both clamps, both sleeves and empty the cooling system.
- Remove the 4 retainers and the flywheel cover

ENG - 136
Engine

Removing the stator

- Remove the electric terminal of the minimum oil


pressure switch.
- Remove the two Pick-Up screws and the screw
holding the wiring support clamp and the 2 stator
fixing screws indicated in the figure.
- Remove the stator and its cable harness.

Refitting the stator

- Refit the stator and the flywheel carrying out the


removal steps but in reverse order, tightening the
retainers to the prescribed torque.
- Place the cable harness as shown in the figure.
- Stator and Pick-up stator
NOTE
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE PIN AS
SHOWN IN THE DETAILED DRAWING.

Locking torques (N*m)


Stator unit screws () 3 4

Refitting the flywheel cover

- Place the flywheel with the top dead center reference aligned with the crankcase reference.
- Prepare the flywheel cover by aligning references between the drive and the crankcase cover.
- Refit the cover on the engine by inserting the three stud bolts in the drive for the water pump.
- Follow the removal procedure but in reverse order.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE FITTED.

ENG - 137
Engine

Flywheel and starting

Removing the flywheel magneto


- Lock the Flywheel rotation using the calliper spanner tool.
- Remove the nut.
- Take out the flywheel.
CAUTION
USING A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STA-
TOR COILS.
NOTE
THE 200CC VERSION FLYWHEEL IS SUPPLIED WITH MORE INERTIA MASS.

ENG - 138
Engine

Inspecting the flywheel components

- Check that the internal plastic parts of the flywheel and the Pick-Up control plate are in good conditions.

Refitting the flywheel magneto

- Fit the flywheel paying attention to insert the key


adequately.
- Lock the flywheel nut to the prescribed torque.
- Check that the Pick-Up air gap is between 0.34
0.76 mm.
The air gap cannot be modified when fitting the
Pick-Up.
Different values result from deformations on the
Pick-Up support.
NOTE
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED.

Specific tooling
020565Y Flywheel lock calliper spanner
Locking torques (N*m)
Flywheel nut 54 60

ENG - 139
Engine

Refitting the starter motor

- Fit and lubricate a new O-ring on the starter mo-


tor.
- Fit the starter motor on the crankcase and lock
the 2 screws to the prescribed torque.

Locking torques (N*m)


Starter motor screws 11 13

Cylinder assy. and timing system

Removing the intake manifold

- Remove the complete flywheel cover as descri-


bed in the flywheel cover chapter.
- Loosen the 3 screws and remove the air intake
manifold.
NOTE
THE 125 CC VERSION IS PROVIDED WITH TAMPER-
PROOF SCREWS.

Removing the timing system drive

- First remove the parts listed below: transmission cover, driving pulley with belt, start-up pinion, oil
sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the pinion
separation washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover indicated in the figure.
- Remove the return spring of the automatic valve-lifter assembly, the automatic valve-lifter assembly
and its end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the 2 clamps indicated in the figure.
- Remove the tensioner and its gasket.
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft control pulley and its washer.
- Remove the command sprocket wheel and the timing chain.
- Remove the screw indicated in the figure, the spacer and the tensioner pad.

ENG - 140
Engine

The tensioner pad must be removed operating from the transmission side. The lower chain guide pad
can only be removed after the head has been removed.
NOTE
It is advisable to mark the chain in order to ensure that the original direction of rotation is maintained.

ENG - 141
Engine

Removing the cam shaft

Remove the 2 screws and the camshaft mounting bracket indicated in the figure.
Remove the camshaft.
Remove the pins and the rocking levers from the flywheel side holes.

ENG - 142
Engine

Removing the cylinder head


- Remove the spark plug.
- Remove the 2 side retainers indicated in the fig-
ure.
- Loosen the 4 head-cylinder fixing nuts in two or
three stages and in a criss-cross sequence.
- Remove the head, the 2 centring dowels and the
gasket.
NOTE
IF NECESSARY, THE HEAD MAY BE REMOVED TOGETH-
ER WITH THE CAMSHAFT, ROCKING LEVER PINS AND
MOUNTING BRACKET. THE HEAD CAN ALSO BE RE-
MOVED WITHOUT TAKING OUT THE CHAIN AND THE
CHAIN TIGHTENER OF THE CRANKSHAFT.

Removing the valves


- Using the appropriate tool fitted with an adapter, remove the cotter pins, plates, springs and valves.
- Remove the oil seals with the specific tool
- Remove the spring lower supports.

ENG - 143
Engine

CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.
Specific tooling
020382Y011 adaptor for valve removing tool
020382Y Tool for removing valve cotters fitted with part 012
020306Y Punch for fitting the valve sealing rings

Removing the cylinder - piston assy.

- Remove the chain guide pad.


- Slide off the cylinder.
- Remove the gasket on the cylinder base.
- Remove the 2 Seeger rings, the pin and piston.
- Remove the piston sealing rings.
CAUTION
TO AVOID DAMAGING THE PISTON, KEEP IT FIRM WHILE REMOVING THE CYLINDER.
NOTE
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.

ENG - 144
Engine

Inspecting the small end

- Measure the inside diameter of the small end using a specific micrometer.
NOTE
REPLACE THE CRANKSHAFT IF THE ROD SMALL END DIAMETER EXCEEDS THE STANDARD
DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING.
Characteristic
Checking the rod small end: Max. diameter
15.030 mm
Checking the rod small end: Standard diameter
15+0.015 +0.025 mm

ENG - 145
Engine

Inspecting the wrist pin

Check the pin outside diameter.


Calculate the rod small end - pin cou-
pling clearance.
Measure the diameter of the bearings
on the piston.
Calculate the pin - piston coupling
clearance.
NOTE
THE PIN HOUSINGS HAVE TWO LUBRICATION CHAN-
NELS FOR THIS REASON MEASURE THE DIAMETER AC-
CORDING TO THE PISTON AXIS.

Characteristic
Pin diameter: Standard clearance
0.015 0.029 mm
Pin diameter: Standard diameter
14.996 15.000 mm
Pin seat diameter on piston: Standard diame-
ter
15.001 15.006 mm
Pin seat diameter on piston: Standard clear-
ance
0.001 0.010 mm

Inspecting the piston

Carefully clean the sealing rings housings.


Measure the sealing rings - grooves coupling clearance using suitable sensors, as shown
in the diagram

ENG - 146
Engine

If clearances measured exceed the limits specified in the table, the piston should be replaced
by a new one. For coupling clearance data, see chapter "Check characteristics/data/As-
sembly clearances"

ENG - 147
Engine

Inspecting the cylinder


Using a bore meter, measure the cyl-
inder inside diameter at three different
points according to the directions
shown in the figure.
Check that the coupling surface with
the head is not worn or misshapen.

Maximum unevenness allowed: 0.05 mm

Pistons and cylinders are classified ac-


cording to their diameter. This coupling
is carried out in pairs (A-A, B-B, C-C,
D-D).

Cylinder grinding should be carried out


with a surfacing that respects the orig-
inal angle.
The cylinder surface roughness should
be 0.9 micron.
This is essential for a good seating of
the sealing rings, which in turn minimi-
ses oil consumption and guarantees
optimum performance.

For the engine 125

Pistons are oversized due to cylinder


grinding and are subdivided into three
categories: 1st, 2nd and 3rd equal to
0.2-0.4-0.6 mm oversize. These are al-
so classified into 4 categories: A, B-B,
C-C, D-D.

Inspecting the piston rings


- Alternately fit the 3 sealing rings in the cylinder in the area where it keeps its original diameter. Using
the piston, fit the rings perpendicularly to the cylinder axis.
- Measure the opening of the sealing rings using a thickness gauge (see picture).
- Replace the piston rings if values higher than those prescribed are measured.
NOTE
BEFORE REPLACING ONLY THE PISTON RINGS, MAKE SURE THAT COUPLING CLEARANCE
BETWEEN THE PISTON RINGS AND ITS GROOVES, AND THAT BETWEEN THE PISTON AND

ENG - 148
Engine

THE CYLINDER ARE AS SPECIFIED. IN ANY CASE, NEW PISTON SEALING RINGS USED IN
COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN
THE STANDARD ONES.

Removing the piston


- Install piston and pin onto the connecting rod, with the piston arrow aligned facing the exhaust.
- Fit the pin snap ring on the appropriate tool.
- With the opening in the position indicated on the tool
S = left
D = right
- Set the snap ring into its position with the punch.
- Fit the pin stop ring using the plug as shown in the figure.
CAUTION
USING A HAMMER MAY DAMAGE THE RINGS HOUSINGS.
NOTE
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.
Specific tooling
020430Y Tool for fitting the pin snap rings
020454Y Tool to fit pin snap rings (200 - 250)

ENG - 149
Engine

Choosing the gasket

- First fit the piston into the cylinder, without any


base gasket.
- Fit a comparator on the specific tool
Support to check piston 020428 position
- Set to zero the comparator by positioning the tool
on an abutment plane. Keeping the zero position,
fit the tool on the cylinder and lock it with the 2 nuts
supplied as shown in the figure.
- Rotate the crankshaft up to TDC (the reversal
point of the dial gauge rotation).
- Place the comparator on the piston as shown in
figure and detect the piston protrusion.
- By means of the chart below, identify the thick-
ness of the cylinder base gasket to be used upon
refitting. By correctly identifying the cylinder base
gasket thickness, an adequate compression ratio
can be maintained
- Remove the specific tool and the cylinder.
NOTE
MEASURE PROTRUSION ON 125 ENGINES, AND RECESS
ON 200 ENGINES.

ENG - 150
Engine

Refitting the piston rings

- Place the oil scraper spring on the piston.


- Fit the oil scraper ring keeping the gap opposed
to the spring union and the word "top" facing the
piston crown. In any case, the chamfered side of
the must be facing the piston crown.
- Fit the middle piston ring with the identification
letter or the word "top" facing the piston crown. In
any case, the tapered side of the ring must be fac-
ing opposite the piston crown.
- Fit the top piston ring with the word "top" or the
reference mark facing the piston crown.
- Offset the piston ring gaps on the three rings by
120 as shown in the figure.
- Lubricate the components with engine oil.
- 200 engines use the top ring with an L-shaped
section.
NOTE
THE 2 PISTON RINGS ARE MADE WITH A TAPERED CY-
LINDRICAL CONTACT SECTION. THIS IS TO OBTAIN A
BETTER BEDDING.

Refitting the cylinder

- Fit the cylinder base gasket of the chosen thickness.


- Using the fork support and the retaining clamp, fit the cylinder as shown in the figure.
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT AND
LUBRICATE THE CYLINDER LINER.
Specific tooling
020393Y Piston fitting ring
020287Y Band for fitting the piston on the cylinder

ENG - 151
Engine

Inspecting the cylinder head

- Using a trued bar and a thickness gauge, check


that the cylinder head surface is not worn or dis-
torted.
Maximum run-out allowed: 0.05 mm
- Check that the camshaft and the rocker pin bear-
ings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and exhaust manifold are not
worn.

Characteristic
bearing A
12.000 12.018
bearing B
20.000 20.021
bearing C
37.000 37.025

ENG - 152
Engine

Inspecting the timing system components

- Check that the guide slider and the tensioner pad


are not excessively worn.
- Check that the chain assembly, the camshaft
driving pulley and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts; if the
chain, pinion or pulley are worn, replace the whole
assembly.
- Remove the central screw with the washer and
the tensioner spring. -Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If signs of wear are found, replace the whole as-
sembly.

Inspecting the valve sealings

- Fit the valves into the cylinder head.


- Alternatively test the intake and outlet valves.
- The test should be carried out by filling the manifold with fuel and checking that the head does not
ooze through the valves when they are just pressed by the fingers.

ENG - 153
Engine

Inspecting the valve housings


- Check the width of the mark on the seat of valve
V. Max. wear: 1.6 mm.
- Remove any carbon deposits from the valve
guides.
- Measure the inside diameter of each valve guide.
- Measure according to the rocker thrust direction
at three different heights.
- If the width of the mark on the valve seat or the
diameter of the valve guide exceed the specified
limits, replace the cylinder head.

Characteristic
Valve seat wear: Intake guide
admissible limit: 5.022
Valve seat wear: Intake guide
Standard diameter: 5.000 5.012 mm
Valve seat wear: Outlet guide
Admissible limit: 5.022
Valve seat wear: Outlet guide
Standard diameter: 5.000 5.012 mm

Inspecting the valves


- Measure the width of the sealing surface on the valve seats and on the valves themselves.

ENG - 154
Engine

Sealing surface width: After use: Intake and outlet: 1.6 mm


- If the sealing surface on the valve is wider than the specified limit, damaged in one or more points or
curved, replace the valve with a new one.
CAUTION
DO NOT CHANGE THE VALVE FITTING POSITION (RH - LH).
Characteristic
Valve wear check: Standard: intake and outlet:
0.99 1.27 mm

- Measure the diameter of the valve stem at the three positions indicated in the diagram.
- Calculate the clearance between the valve and its guide.
- Check that there are no signs of wear on the faying surface with the set screw articulated terminal.
- If no anomalies are found during the above checks, the same valves can be reused. For better sealing
results, it is advisable to grind the valves. Grind the valves gently with fine-grained lapping compound.
Upon grinding, keep the cylinder head in horizontal position. This will prevent the lapping compound
residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPING
COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A
SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
NOTE
DO NOT CHANGE THE VALVE FITTING POSITION
Characteristic
Valve check: standard length
Outlet: 94.4 mm
Valve check: standard length
Inlet: 94.6 mm
Valve check: maximum clearance allowed:
Outlet: 0.072 mm
Valve check: maximum clearance allowed
Inlet: 0.062 mm
Valve check: standard clearance:
Outlet: 0.025 0.052 mm
Valve check: standard clearance:
Inlet: 0.013 0.040 mm
Valve check: Minimum diameter allowed:

ENG - 155
Engine

Outlet: 4.95 mm
Valve check: Minimum diameter allowed:
Inlet: 4.96 mm
Valve check: Standard diameter:
Inlet: 4.972 4.987 mm
Valve check: Standard diameter:
Outlet: 4.96 4.975 mm

ENG - 156
Engine

Inspecting the springs and half-cones

- Check that the spring upper caps and the cotters show no signs of abnormal wear.

Refitting the valves

- Lubricate the valve guides with engine oil.


- Place the valve spring supports on the head.
- Using the specified punch, fit the 4 sealing rings.
- Fit the valves, the springs and the plates. Using the specified tool with the appropriate adaptor, com-
press the springs and insert the cotters in their seats.
NOTE
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-
ERENCE COLOUR ON THE COTTERS SIDE (TURNS WITH GREATER PITCH).
Specific tooling
020306Y Punch for fitting the valve sealing rings
020382Y Tool for removing valve cotters fitted with part 012
020382Y011 adaptor for valve removing tool

ENG - 157
Engine

Inspecting the cam shaft

- Check the camshaft bearings for signs of abnormal wear.


- Check the cam height.
- Check there is no wear on the camshaft groove and related retention plate.
- If values measured are not within the specified limits or there are signs of excessive wear, replace the
defective components with new ones.
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of-stroke roller, or the
rubber buffer on the automatic valve lifter retaining cover.
- Check the automatic valve-lifter return spring is not deformed by over-stretching.
- Replace any defective or worn component.
- Check there are no signs of wear or scoring on the rocker pins.
- Check the internal diameter of each rocker arm.
- Check there are no signs of wear on the contact pads with the cam and on the jointed adjustment
plate.

Characteristic

ENG - 158
Engine

Rocking levers inside diameter: Standard diameter


12.000 12.011 mm
Rocking lever pins diameter: Standard diameter
11.977 11.985 mm
Camshaft check: Maximum axial clearance admitted:
0.42 mm
Camshaft check: Standard axial clearance:
0.11 0.41 mm
Camshaft check: Standard height
Outlet: 29.209 mm
Camshaft check: Standard height
Inlet: 30.285 mm
Camshaft check: Minimum diameter admitted
Bearing B : 19.950 mm
Camshaft check: Minimum diameter admitted
Bearing A : 36.94 mm
Camshaft check: Standard diameter
Bearing B : 19.959 19.98 mm
Camshaft check: Standard diameter
Bearing A : 36.95 36.975 mm

ENG - 159
Engine

Refitting the head and timing system components

- Fit the timing chain sprocket wheel on the crank-


shaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the chain tensioner pad from the cylinder head
side.
- Fit the spacer and the fixing screw.
- Tighten the screw to the prescribed torque.
- Fit the pins and rocker levers.
- Lubricate the 2 rocking levers through the holes
at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams opposed to the
rocking levers.
- Insert the retention plate and tighten the two
screws shown in the picture to the prescribed tor-
que.

ENG - 160
Engine

- Refit the spacer on the camshaft.


- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- In this position, fit the chain onto the camshaft
control pulley.
- Insert the pulley on the camshaft while keeping
the reference 4V matching the reference mark on
the head.
- Fit the counterweight and tighten the fixing screw
to the prescribed torque..
- Fit the end-stop ring on the automatic valve-lifter
assembly and fit the automatic valve-lifter cam to
the camshaft.
- Fit the automatic valve-lifter return spring.
During this operation the spring must be loaded
approximately 180.
- Fit the automatic valve-lifter retaining dish, using
the counterweight fixing screw as reference.
- Tighten the central fixing screw to the prescribed
torque.
- Set the tensioner slider to its home position.
- Fit the chain tensioner on the cylinder using a
new gasket, and tighten the 2 screws to the pre-
scribed torque.
- Insert the chain tensioning spring, together with
the central screw and washer, and tighten the cap
to the prescribed torque.
- Adjust valve clearance
- Fit the spark plug.
Electrode gap: 0.8 mm
NOTE
GREASE THE END-STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.

Locking torques (N*m)


Timing chain tensioner support screw 11 13
Spark plug 12 14 Starter ground screw 7 8.5
Timing chain tensioner pad screw 10 14 Starter
ground bell screw 11 15 Timing chain tension-
er central screw 5 6 Camshaft retention plate
screw 4 6

ENG - 161
Engine

- Fit the timing chain guide pad.


- Insert the centring dowels between the cylinder head and the cylinder, fit the cylinder head gasket and
the cylinder head.
- Lubricate the stud bolt threading.
- Tighten up the nuts to a pre-torque of 71 Nm
- Carry out an angle rotation of 180 (2 rotations of 90each)
- To carry out the operations described above, follow the tightening sequence indicated in the figure.
- Fit the two screws on the timing chain side and tighten them to the prescribed torque.
NOTE
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN
USING A JET OF COMPRESSED AIR.
Locking torques (N*m)
Timing chain tensioner support screw 11 13

ENG - 162
Engine

ENG - 163
Engine

Refitting the intake manifold

- Assemble the inlet manifold and tighten the 3


screws.
NOTE
FOR THE SPECIAL SCREWS OF THE 125 CC VERSION,
USE COMMERCIAL INSERTS AND INSERT HOLDERS.

Crankcase - crankshaft

Splitting the crankcase halves


engine crankcase opening

ble>

- First remove the following

units:

transmission cover, driving

pulley, driven pulley and belt,

rear hub cover, gears, bear-

ings and oil seals as descri-

bed in the transmission

chapter.

Remove the oil sump, the by-

pass, the chain compartment

cover and the oil pump as de-

scribed in the lubrication

chapter.

- Remove the flywheel cover with the water pump, the fly-

wheel, the stator as described in the magneto flywheel

chapter.

- Remove the oil filter and the oil pressure switch.

- Remove the cylinder-piston-head unit as described in the

timing system cylinder head chapter.

- Remove the 2 retainers indicated in the figure and the starter

motor.

ENG - 164
Engine

- Before opening the crank-

case, it is advisable to check

the axial clearance of the

crankshaft. To do this, use a

plate and a support with a

specific tool dial gauge.

- Higher clearances are signs

of wear on the supporting sur-

faces of the crankshaft on the

crankcase.

- Remove the 11 crankshaft

coupling screws.

- Separate the crankcase

while keeping the crankshaft

in one of the two crankcase

half.

- Remove the crankshaft.

- Remove the crankshaft

halves coupling gasket.

- Remove the two screws and

the internal cover shown in

the figure.

- Remove the flywheel side oil

seal.

- Remove the oil filter fitting

shown in the figure.

- Check the connecting rod

axial clearance.

- Check the connecting rod

radial clearance.

- Check that the surfaces that

limit the axial clearance are

not scored and with the aid of

a gauge measure the crank-

shaft width as shown in the

figure.

Shimming (only 200 cc)

ENG - 165
Engine

- Check shim washer thick-

ness.

- Check that shim washers

are not scored.

- If the crankshaft-crankcase axial clearance exceeds what

specified and the crankshaft does not show any defect, the

problem must be due to either excessive wear or wrong ma-

chining on the crankcase.

- Check the diameters of both

crankshaft bearings accord-

ing to the axes and surfaces

shown in the figure. Half-

shafts are classified in two

categories, Cat 1 and Cat 2,

as shown in the chart below.

CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN ITS WIDTH IS
WITHIN THE STANDARD VALUES AND SURFACES SHOW
NO SIGNS OF SCORING.
CAUTION
WHEN OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
CAUTION
WHEN SEPARATING THE CRANKCASE KEEP THE
CRANKSHAFT IN ONE OF THE CRANKCASE HALF. THE
CRANKSHAFT MIGHT ACCIDENTALLY FALL IF THIS
RULE IS NOT OBSERVED.
NOTE
IN CASE OF REUSE, KEEP THE ORIGINAL FITTING POSI-
TION.
NOTE
WHEN MEASURING THE CRANKSHAFT WIDTH, MAKE
SURE THAT THE MEASUREMENTS ARE NOT MODIFIED
BY THE COUPLING SPOKES WITH THE CRANKSHAFT
BEARINGS.
NOTE
The 200 cc version crankshaft is fitted with two steel shim
washers. Take note of the fitting position.

Specific tooling
020262Y Crankcase splitting strip
Characteristic
Camshaft bearings: Standard diameter: Cat. 2
29.000 29.006
Camshaft bearings: Standard diameter: Cat. 1

ENG - 166
Engine

28.994 29.000
Engine crankcase opening: Standard thick-
ness
2.175 2.225 mm
Crankshaft width with shim washers: standard
sizes
51.40 51.45 mm
Engine crankcase opening: standard sizes
55.75 55.90 mm (125)
Crankshaft - connecting rod radial clearance:
Standard clearance
0.036 0.054 mm
Crankshaft - connecting rod axial clearance:
Standard clearance
0.20 0.50 mm
Crankshaft - crankcase axial clearance: Stand-
ard clearance
0.15 0.40 mm (when cold)

Inspecting the crankshaft alignment

- Install the crankshaft on the support and measure


the misalignment at the 4 points indicated in figure.
- Check that the crankshaft cone, the tab fitting, the
oil seal flow, the knurling and the threaded tabs are
in good working order.
- In case of failure, replace the crankshaft.
The rod head bushings cannot be replaced. There-
fore, the connecting cannot be replaced either
and, when cleaning the crankshaft, be very careful
that no impurities get in through the shaft lubrica-
tion holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
NOTE
CRANKCASE BEARINGS ARE NOT GRINDABLE .

ENG - 167
Engine

Specific tooling
020074Y Support base for checking crankshaft
alignment

Characteristic
Maximum off-line allowed:
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm

CRANKSHAFT ALIGNMENT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft alignment

Measure the flows on both X-Y axles

STANDARD DIAMETER (125 - 200 CC)


Name Description Dimensions Initials Quantity
Cat. 1 28.998 29.004
Cat. 2 29.004 29.010

Maximum off-line allowed:


A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
Specific tooling
020335Y Dial gauge magnetic support

ENG - 168
Engine

020074Y Support base for checking crankshaft alignment

Inspecting the crankcase halves


- Before checking the crankcase halves, thoroughly clean all the surfaces and oil pipes.
- For the crankcase half on the transmission side, take particular care when cleaning the housing and
oil pipes of the oil pump, the duct and the by-pass valve, the main bushings and the cooling nozzle on
the transmission side (see figure).
As already described in the lubrication chapter, it is especially important that the by-pass valve housing
shows no wear that may impair the proper sealing of the lubrication pressure adjustment piston.
- For the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings,
the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the flywheel side oil
seal.
- Check the coupling surfaces for scratches or deformation, paying special attention to the cylinder/
crankcase surfaces and the crankcase halves coupling surfaces.
- Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in
oil pressure and thus affect the lubricating pressure for the main bushings and the connecting rod.
- Check that the surfaces limiting the crankshaft axial clearance show no signs of wear. To measure
and check sizes follow the procedure described previously for checking crankshaft axial clearance and
dimensions.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT
IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO
DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKAGE CAN CONSIDERABLY
CAUSE A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CONNECTING
ROD.
NOTE
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET: THIS GIVES A "LOW
PRESSURE" HEAD LUBRICATION; THIS CHOICE HAS BEEN MADE TO REDUCE OIL TEMPER-
ATURE. JET CLOGGING IMPAIRS HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET
FAILURE CAUSES A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CON-
NECTING ROD.

ENG - 169
Engine

Inspecting the crankshaft plain bearings

Refitting the crankcase halves

- Fit the internal bulkhead by locking the 2 screws


to the prescribed torque.
- Fit the oil filter fitting and tighten it to the prescri-
bed torque.
- Place a new gasket on one of the crankcase half,
preferably on the transmission side, together with
the centring dowels.
- Lubricate the main bushings and insert the crank-
shaft in the transmission side crankcase half.
- Couple the 2 crankcase halves.
For the 200 version, reposition shim washers as in
the original fitting.
- Fit the 11 screws and tighten them to the pre-
scribed torque.
- Lubricate the flywheel side oil seal.
- Use the appropriate tool to assemble the oil seal.
- Fit and lubricate a new O-ring on the pre-filter.

ENG - 170
Engine

- Insert the pre-filter and its cover on the engine.


Tighten to the specified torque.
NOTE
FAILURE TO USE THE SPECIFIC TOOL MAY RESULT IN
AN INCORRECT DEPTH POSITION AND, AS A CONSE-
QUENCE, IN INADEQUATE OIL SEALING.

Specific tooling
020425Y Punch for flywheel side oil seal

Locking torques (N*m)


Screws for engine crankcase internal bulk-
head (transmission-side half shaft) 4 6 Oil fil-
ter fitting on crankcase 27 33 Engine crank-
case coupling screws 11 13 engine oil
drainage plug/mesh filter 24 30

Lubrication

Conceptual diagrams

LUBRICATION CIRCUIT

ENG - 171
Engine

ENG - 172
Engine

Oil pressure check

- After removing the flywheel covers as described in the "Flywheel" chapter, disconnect the electrical
connection of the minimum oil pressure switch and remove the switch.
- With the engine idling at 1650 rpm and the oil temperature at ~90C, check that the oil pressure is
between 0.5 1.2 atm.
- With the engine idling at 6000 rpm and the oil temperature at ~90C, check that the oil pressure is
between 3.2 4.2 atm.
- Remove the specific tools on the engine once the measurement is complete. Refit the oil pressure
switch and washer, tightening it to the prescribed torque, and fit the flywheel cover.
- If oil pressure reading are not within the specified limits, check in the following order: the oil filter, the
oil by-pass valve, the oil pump and the crankshaft seals.
NOTE
THIS CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL
FILTER IN GOOD CONDITION.
Specific tooling
020193Y Gauge for oil pressure check
020434Y Fitting for oil pressure check
020331Y Digital multimeter

ENG - 173
Engine

Oil pump

- Check there are no signs of wear on the oil pump shaft or body.
- Check there are no signs of wear or scoring on the oil pump cover.
- If non-conforming values or signs of wear are found, replace the faulty parts or the assembly.
- Fit the pump cover so positioned that the holes for the crankcase fixing screws are aligned.
- Make sure the gasket is the correct position and refit the pump on the engine crankcase. The pump
can only be fitted in one position. Tighten the screws to the prescribed torque.
- Fit a new O-ring on the pinion.
- Assemble the chain.
- Fit the central screw and the belleville washer. Tighten to the specified torque.
- Assemble the oil pump cover by tightening the two screws to the prescribed torque.
NOTE
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE
THAT THE PUMP TURNS FREELY.
Locking torques (N*m)
Screws fixing oil pump to crankcase 5 6 oil pump driving crown gear screw 10 14 Oil pump
cover screws 0.7 0.9

ENG - 174
Engine

Removal

- Always use a new oil seal when refitting.


-Prepare the new oil seal by lubricating its sealing
lip.
- Preassemble the oil guard with the appropriate
tool, positioning the screws.
- Place the sheath on the crankshaft.
- Insert the tool with the oil seal fitted on the crank-
shaft until it comes into contact with the crankcase.
- Position the oil seal by inserting the bracket which
is part of the appropriate tool.
- Tighten the threaded bar onto the crankshaft up
as far as it will go.
- Use the nut to move the base of the tool until you
can feel the oil seal driving fully into position.
- Remove all of the tool components following the
procedure in reverse order.
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ON THE EN-
GINE CRANKCASE
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. ONCE THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
COUPLING SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP DRIVING
CHAIN

Specific tooling
020622Y Transmission-side oil seal punch

ENG - 175
Engine

- Undo the 2 clamping screws in the figure and re-


move the cover of the pump control pulley.
- Block the rotation of the oil pump driving pulley
by inserting a screwdriver through one of its holes.
- Remove the central screw with Belleville washer
indicated in the figure.
- Remove the chain.
- Remove the control sprocket wheel and its O-
ring.
- Remove the oil pump by unscrewing the 2 screws
indicated in the figure.
- Remove the sealing gasket.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.

Inspection
- Remove the two screws and the oil pump cover.
- Remove the circlip fixing the inner rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the 2 reference marks visible. Fit the Seeger ring.
- Measure distance between rotors with a thickness gauge at the position shown in the picture.

ENG - 176
Engine

- Measure the distance between the outer rotor and the pump body (see figure).
- Check the axial clearance of the rotors using a trued bar as shown in the figure.

Characteristic
Rotor axial clearance:
Limit value allowed: 0.09 mm
Distance between outer rotor and pump body
limit clearance allowed: 0.20 mm
Distance between rotors
limit clearance allowed: 0.12 mm

ENG - 177
Engine

Removing the oil sump

- Remove the oil filler plug, the transmission cover,


the complete driving pulley assembly with belt and
sprocket wheel, as described in the "Transmis-
sion" chapter.
- Drain the oil from the sump as described above.
- Remove the 7 screws, shown in the figure, and
the 2 brackets fixing the rear brake fluid pipe.
- Remove the spring, the by-pass piston, the gas-
ket and the centring dowels shown in the figure.

Inspecting the by-pass valve

- Check the free length of the spring.


- Check that the plunger is not scored.
- Make sure that it slides freely on the crankcase and that it guarantees a good seal.
- Otherwise, eliminate any impurities or replace defective parts.

Characteristic
By-pass check: Standard length
54.2 mm

ENG - 178
Engine

Refitting the oil sump

- Refit the by-pass valve plunger in its housing.


- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the two centring dowels.
- Refit the sump, taking care to locate the spring in the appropriate piece found in the sump.
- Refit the screws and supporting brackets of the rear brake pipes in the reverse order followed for
removal.
- Tighten the screws to the prescribed torque.
- Refit the driving pulley assembly, the belt, the pinion and the transmission cover as described in the
"Transmissions" chapter.
- When testing the lubrication system, refer to the "Crankcase and Crankshaft" chapter regard-
ing lubrication of the crankshaft and connecting rod.

Locking torques (N*m)


Oil sump screws 10 14

ENG - 179
Engine

SAS valve

Inspecting the one-way valve


Remove the SAS valve.
- Provisionally assemble the rubber sleeve at the SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rubber sleeve as shown in the photograph.
- Set the pump to the low-pressure mode (VACUUM).
- Operate the pump slowly.
- Check that the oneway valve allows the air to pass through, causing a slight vibration.
- Switch the pump to the pressure mode (PRESSURE).
- Operate the pump slowly and check if there is a perceptible increase in pressure. A small leak is to
be considered as normal.
If failures are detected, replace the pump.
NOTE
A MALFUNCTIONING ONEWAY VALVE CAN RESULT IN RUBBER SLEEVE AND FILTER OVER-
HEATING.
NOTE
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING
Specific tooling
020329Y MityVac Vacuum pump

Inspecting the cut-off


Remove the SAS valve.
- Connect the MITYVAC pump in low-pressure mode (VACUUM) to the CUT-OFF valve vacuum intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept at all times.
- If a worn seal is detected, replace it.

ENG - 180
Engine

- With a "T" bypass and flexible rubber hoses make a parallel connection between the rubber sleeve
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump to the low-pressure mode (VACUUM).
- Using a pair of long flat needle-nose pliers, choke the rubber hose close to the valve.
- Operate the pump until vacuum is over 0.5 BAR.
- Release the hose and check how the vacuum reacts. - Under normal operation conditions the vacuum
undergoes a slight fall and then readjusts. This is followed by a slow and continuous loss of pressure
up to approx. 0.4 BAR.Now the valve opens and pressure is suddenly set to zero.
Lack of tightness or the fact that the valve opens at different pressure values should be regarded as
faults.Should this occur, replace it.
NOTE
LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS IN EXHAUST NOISE (EXPLOSIONS IN
THE MUFFLER).INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT IN CATALYTIC
CONVERTER MALFUNCTION
NOTE
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES JEOPARDISING THE CORRECT OPERA-
TION OF THE CUT-OFF VALVE, CAN ALSO COMPROMISE THE IDLE CORRECT FUNCTIONING
Specific tooling
020329Y MityVac Vacuum pump

ENG - 181
Engine

ENG - 182
Engine

Fuel supply

- To clean the filtering element proceed as follows: remove the 4 screws fixing the filter cover that are
indicated in the figure; remove the cover and the paper filtering element; clean by blowing compressed
air and then refit.
- Make sure the filtering element is in the correct position.
- Check that the air passage sections are not distorted or broken.
- Check that the filter housing cover coupling is adequately sealed.
NOTE
FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RESULT IN WRONG VACUUM INSIDE THE
FILTER HOUSING WHICH IN TURN, MAY CAUSE VARIATIONS IN THE CARBURETION.

Removing the carburettor

Remove the fuel tank,


Remove the right inspection cover,
Remove the central inspection cover,
Disconnect the connector.

ENG - 183
Engine

Remove the clamp and slide off the


heater pipe 1.
Plug the heater pipe 1 so that cool-
ant does not spill out.

Loosen the clamp 2 of the intake manifold sleeve 3.


NOTE
THE CARBURETTOR IS NOW CONNECTED TO THE THROTTLE CABLE. OPERATE WITH CAU-
TION SO AS NOT TO DAMAGE ANY COMPONENT.
Release the carburettor from the
sleeve 3 and partially remove it.
CAUTION
OPERATE WITH CAUTION. DO NOT DAMAGE THE FIXING
TONGUES WHEN REMOVING THEM.

Fully unscrew the nut 4 that locks the


throttle grip cable 5.
Slide off the throttle grip cable 5 from
its seat.
Slide off the throttle grip cable head
6 form the linkage system catch.

Loosen the clamp and slide off the car-


burettor.

ENG - 184
Engine

Remove the clamp.


Slide off the heater pipe 7.
Completely remove the carburettor.

Kehin

- To detach the carburettor from the engine, it is


necessary to detach the air filter and remove the
throttle control transmission, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, and the intake
fitting.
- Slide off the carburettor and rotate it so that the
screw with the water joint and the pipes can be
removed.
NOTE
THIS LAST OPERATION IS NECESSARY SO AS NO TO
EMPTY THE COOLING SYSTEM.

- Remove the protection, the bracket and the start-


er by undoing the screw shown in the figure.

ENG - 185
Engine

- Remove the 2 screws and the starter support to-


gether with the gasket.

- Remove the clamp and the cover with the airing


filter of the diaphragm chamber.

- Remove the 4 fixing screws shown in the figure


and the vacuum chamber cover.
WARNING
UPON REMOVING THE CARBURETTOR COVER, PAY AT-
TENTION NOT TO RELEASE THE SPRING ACCIDENTAL-
LY.

ENG - 186
Engine

- Remove the vacuum valve and the diaphragm;

- Unscrew the bayonet joint 1/8 of a turn and re-


move it; take out the spring and the vacuum valve
needle.

- Remove the 4 screws shown in the figure.

- Remove the chamber together with the acceler-


ating pump, its control and gasket.

ENG - 187
Engine

- Remove the sealing gasket.


- Remove the intake and outlet valves of the ac-
celerating pump from the float chamber
NOTE
BE CAREFUL THAT THE ACCELERATING PUMP VALVES
ARE MADE UP OF NOZZLES, SPRING AND BALL.
NOTE
AVOID REMOVING THE PISTON OF THE ACCELERATING
PUMP AND ITS CONTROL.

Adequately support the carburettor and with a pin


and hammer remove the float pin by acting on the
throttle control side.
- Remove the float and the pin.
- Remove the maximum jet

- Remove the maximum jet.

ENG - 188
Engine

- Remove the diffuser.

- Remove the sprayer.


NOTE
WHEN CLEANING THE CARBURETTOR BODY REMOVE
THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY-
ER IS FORCED INTO ITS POSITION, DO NOT ATTEMPT TO
REMOVE IT AS THIS WILL ONLY DAMAGE IT.

ENG - 189
Engine

- Remove the minimum jet.

- Remove the minimum flow set screw and the


spring.
CAUTION
DO NOT TRY TO REMOVE PARTS EMBEDDED IN THE
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
NEEDLE SEAT, STARTER NOZZLE, TRAP COVER FOR
PROGRESSIONS AND INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT.DO NOT REMOVE THROTTLE-TO-SHAFT CON-
NECTING SCREWS. THE FIXING SCREWS ARE CAULKED
AFTER BEING FITTED AND REMOVING THEM DAMAGES
THE SHAFT.

Adjusting the idle

The engine does not require frequent idle speed


adjustments, but it is essential to strictly follow cer-
tain rules when adjusting idle speed.
Before adjusting the carburettor, make sure that
the lubrication requirements and valve clearance
are met, timing is respected, the spark plug is in
optimum conditions, the air filter is clean and
sealed, and the exhaust system is perfectly
sealed.

Warm up the engine, letting it run at 50


km/h for at least 5 minutes.
Connect the multimeter thermometer
(020331y) to the sump, using a cap
with oil expressly prepared for probes.

ENG - 190
Engine

Start the engine and before adjusting


idle speed, make sure that the oil tem-
perature is between 70 80 C
Using the analyser rpm indicator or any
other instrument (020332y), adjust the
idle screw to obtain 1600 1700 rpm.

- The engine does not need frequent idle adjust-


ments, however it is very important to make any
adjustments fully respecting some standards.
- Before adjusting the carburettor make sure to re-
spect the lubrication requirements, valve clear-
ance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 mi-
nutes at approximately 50 kph.
- Connect the vehicle to the exhaust fumes analy-
ser inserting the probe into a sealed extension pipe
placed at the muffler exit end.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly pre-
pared for probes.
- Start the motor and before adjusting the idle
speed make sure that the oil temperature is be-
tween 70 80C.
- Using the rpm indicator or any other instrument
(020332y), adjust the idle screw to obtain 1600
rpm 1700 rpm
- Adjust the flow screw until the carbon monoxide
(CO) percentage is 3.1 4.5%, when the screw is
loosened the CO value rises (rich mix). Tightening
the screw decreases the CO (lean mix).
- If the adjustment of the flow screw causes a rpm
increase readjust the revs again and if necessary,
the flow screw to reach stable values.

ENG - 191
Engine

- When the oil temperature, the numbers of revs


and the percentage of carbon monoxide are re-
spected the idle carburetion is considered correct.
From the analyser we can draw further informa-
tion:
- carbon dioxide percentages (CO2), the percent-
age of carbon dioxide has an inverted course com-
pared to the percentage of(CO), values over
12.5% are considered correct. Non complying val-
ues indicate lack of tightness in the exhaust sys-
tem.
- Unburned hydrocarbons (HC) are measured in
parts per million (PPM). The HC value decreases
while the rpm increases; with the engine at idle it
is normal to detect 200 400 PPM, these emission
values are deemed normal for an engine with a
diagram of distribution for motorcycles. Higher val-
ues can cause loss of engine blows as the mixture
is too lean (low CO), ignition failure or, incorrect
timing or a clogged or unsealed exhaust valve.
- If it were difficult to ???? adjustment CO check
accurately:
- That the carburettor is clean
- That the automatic starter is efficient
- Tapered pin housing efficiency
- Tank level adjustments
NOTE
THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE IF INADEQUATE RPM INDICATORS ARE USED.
CORRECT COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN ALSO READ RPM OVER 6000
8000

ENG - 192
INDEX OF TOPICS

SUSPENSIONS SUSP
Suspensions

Front

Removing the front wheel

KEY:
1. Grey front wheel rim;
2. Bearing;
3. Spacer;
4. Front wheel left spacer;
5. Front wheel right spacer;
6. Front wheel pin;
7. Tubeless valve;
8. Front brake disc;
9. TE flanged screw;
10. Front cover;
11. Oil seal;
12. Cap.

SUSP - 194
Suspensions

Rest the scooter on its centre stand.

Place a support under the chassis.


Remove the brake calliper.
Loosen the pin locking screw.
CAUTION
UPON REMOVING/REFITTING, PAY ATTENTION NOT TO
DAMAGE THE BRAKE HOSES, DISCS AND PADS.

Unscrew and remove the wheel pin.


Collect the spacers from the wheel left
and right sides.

Remove the wheel.


CAUTION
DO NOT ACTUATE ON THE FRONT BRAKE LEVER AFTER REMOVING THE WHEEL, OTHER-
WISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT, RESULTING IN BRAKE FLUID
LEAKAGE.
To refit, carry out removal operations but in reverse order.

Front wheel hub overhaul

Remove the front wheel.


Clean the two sides of the hub with a
cloth.
Remove the right oil seal 1.
Remove the right bearing 2 with a
suitable extractor.
Remove the left oil seal 3.
Remove the left bearing 4 with a
suitable extractor.
Carry out a thorough check of the bear-
ings.
Collect the internal spacer 5.
Clean the inside of the hub thoroughly.

SUSP - 195
Suspensions

Wash all the parts with clean deter-


gent.
CAUTION
UPON REFITTING, USE A BUFFER WITH A DIAMETER
EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO
INSERT THE BEARINGS. DO NOT HIT THE BALLS AND/OR
THE INTERNAL RING. MAKE SURE THE FOLLOWING
COMPONENTS ARE FITTED PERFECTLY IN:
THE LEFT BEARING 4 ON THE HUB;
THE SPACER 5 ON THE LEFT BEARING
4;
THE RIGHT BEARING 2 ON THE SPACER
5;

BEARINGS
Manually rotate the internal ring 1 which must
turn smoothly, without obstacles and/or noise.
There must be no axial clearance. The bearings
presenting these problems must be replaced.
CAUTION
CHECK THAT ALL THE PARTS ARE IN GOOD CONDI-
TIONS, SPECIALLY THE ONES BELOW.

GASKETS
Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive
wear.

WHEEL PIN
Using a dial gauge, check the wheel pin 2 ec-
centricity. Replace the pin 2 if the eccentricity
exceeds the limit value.

Characteristic
Maximum eccentricity:
0.25 mm

RIM
Using a dial gauge, check that the radial eccen-
tricity A and the axial eccentricity B of the rim
3 do not exceed the limit value.
An excessive eccentricity is usually caused by
worn or damaged bearings.
Replace the rim 3 if, after the bearings are re-
placed, the value is not within the specified limit.

Characteristic
Maximum radial and axial eccentricity:

SUSP - 196
Suspensions

2 mm

Check the tyre conditions.


CAUTION
CHECK TYRE TREAD FOR WEAR. BADLY WORN TYRES
COMPROMISE TRACTION AND VEHICLE HANDLING.
REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC-
TURE BIGGER THAN 5 MM IN THE TREAD. SOME TYRE
TYPE-APPROVED FOR THIS VEHICLE FEATURE WEAR
INDICATORS. CHECK THAT THE INFLATION VALVES 1
HAVE THEIR CAPS FITTED IN ORDER TO AVOID UNEX-
PECTED FLAT TYRES.
BALANCE THE WHEEL AFTER A TYRE IS MENDED.

Handlebar

Removal

Remove the front handlebar cover.


Remove the rear handlebar cover.
Undo the three screws indicated and
remove the lower shell.

Undo the indicated screw and remove


electric controls fittings.
Disconnect the connectors of the elec-
tric controls and release the handlebar
from the cable harness.

SUSP - 197
Suspensions

Unscrew the two screws and remove


the u-bolt fixing the brake pump.
Repeat the operations now for the left
brake pump.

Undo the safety screw and handlebar


fixing screw; collect the washer.
Remove the handlebar from the steer-
ing tube.

Remove the throttle grip from the han-


dlebar.

To refit, carry out removal operations but in reverse order

Locking torques (N*m)


Locking torque value in Nm

SUSP - 198
Suspensions

Front fork

KEY:
1. Fork base
2. Fork clamp screws
3. Snap ring
4. Rubber cap
5. Sealing cap
6. O-ring
7. Spring
8. Pumping member
9. Counter spring
10. Bottom buffer
11. Left stem
12. Dust guard gasket
13. Safety circlip
14. Sealing gasket
15. Cap
16. Bushing
17. Left wheel holder
18. Sealing washer
19. Lower screw

SUSP - 199
Suspensions

20. Right stem


21. Right wheel holder
22. Locking screw

Removal

STEM REMOVAL

Remove the front wheel.


Remove the front mudguard.
Undo and remove the two screws 1.
NOTE
THE FOLLOWING OPERATIONS REFER TO REMOVING
ONLY ONE WHEEL HOLDER STEM - SLEEVE, BUT THEY
APPLY TO BOTH.

Remove the shield back plate.


Remove the upper Seeger ring 2.
Remove the wheel holder stem -
sleeve.

OIL EMPTYING
Place the sleeve in a vice fitted with protection
jaws (aluminium).
NOTE
GET A COLLECTING CONTAINER BEFORE CARRYING
OUT THESE OPERATIONS.
CAUTION
THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS
OIL. DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN
REMOVING IT.

SUSP - 200
Suspensions

Remove the upper closing cap.

Lower the pumping element until the


Seeger ring 1 can be removed.
Remove the Seeger ring 1.

Remove the cap and the O-ring.

Remove the spring and wait some mi-


nutes so that the oil deposited on it
drips off.

SUSP - 201
Suspensions

Drain off the oil into the collecting con-


tainer by pumping it out with the stem.

WHEEL HOLDER STEMS SLEEVES REMOVAL

Drain off the oil.


Place the stem in a vice fitted with pro-
tection jaws (aluminium).

Undo and remove the lower screw 1.

Remove the stem and collect the cen-


tring bushing.
NOTE
BE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIOR
WHEN REMOVING THE DIFFERENT COMPONENTS.

SUSP - 202
Suspensions

Remove the pumping member 2 and


the spring 3 from the stem.

Remove the dust guard from the


sleeve.

Remove the Seeger ring.

Remove the oil seal.

SUSP - 203
Suspensions

Remove the washer.

If necessary, remove the spacer 4.

Overhaul

Components check
Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing
them with wet sandpaper (fine grain).

If the scorings are deep, replace the stem.


Use a dial gauge to check that the stem bending is below the limit value.
If over the value, replace the stem.
CAUTION
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE
WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
Bending limit:
0.2 mm

SUSP - 204
Suspensions

Check that there are no damages and/


or cracks; otherwise, replace it.
If there are signs of excessive wear or
damage, replace the affected compo-
nent.

Replace the following components with new ones:

O-ring gasket on the cap 1;

oil seal 2;
dust guard 3;

Refitting

Place the sleeve in the vice fitted with


protection jaws (aluminium).
Fit the spacer 1.
CAUTION
BE EXTREMELY CAREFUL SO THAT NO FOREIGN BOD-
IES GET INTO THE SLEEVE OR THE WHEEL HOLDER
STEM.

Insert the washer.


NOTE
SPREAD A THIN LAYER OF FORK OIL ON GASKETS AND
BUSHINGS BEFORE REFITTING THEM.

SUSP - 205
Suspensions

Insert the oil seal.

Fit the Seeger ring.

Fit the dust guard.

Insert the pumping member and the


spring in the stem.

SUSP - 206
Suspensions

Fit the components below on the


sleeve in the following order: the cen-
tring bushing 2 and the stem.

Tighten the lower screw 3.


Refill with oil.

OIL FILLING

Place the wheel holder stem sleeve


unit in a vice fitted with protection jaws
(aluminium).

Fit the spring.

SUSP - 207
Suspensions

Pour fork oil into the wheel holder stem


sleeve unit.
CAUTION
NEVER REUSE OIL.

Remove the cap with the O-ring.

Fit the pumping member 1.

Lower the pumping element until the


Seeger ring 2 can be fitted.
Fit the Seeger ring 2.

SUSP - 208
Suspensions

Fit the upper closing cap.

Steering column

KEY:
1. Cap;
2. Lock nut;
3. Adjusting nut;
4. Upper dust guard;
5. Upper bearing;
6. Separating ring;
7. Lower bearing;
8. Lower dust guard.

SUSP - 209
Suspensions

Steering bearing
Check that the ball contact area 1 on the rotating
seat 2 and on the fixed seat 3 is not damaged
or too worn. Replace the whole bearing if neces-
sary.
CAUTION
CHECK THAT THE COMPONENTS ARE IN GOOD CONDI-
TIONS.
CAUTION
APPLY GREASE ON BALL CONTACT AREAS ON BOTH
SEATS 2 AND 3.

Rear

Removing the rear wheel

KEY:
1. Grey rear wheel rim;
2. Rear cover;
3. Internal wheel spacer;
4. External wheel spacer;
5. Nut;
6. Cap;
7. Split pin;

SUSP - 210
Suspensions

8. Brake disc;
*9. TE flanged screw;
10. SPEED SENSOR screw;
11. Tubeless valve.

Park the vehicle on its centre stand.


Remove the exhaust silencer.
Remove the right rare shock absorber.
Slide off the rear brake calliper, keeping it linked to the oil pipe.
Remove the split pin 7 placed on the wheel pin.
Remove the cap 6.
Unscrew and remove the wheel pin nut 5 and the shim washer 4.

Undo and remove the two screws and remove the muffler support plate.
Remove the spacer 3 placed on the wheel pin.
Remove the rear wheel by sliding it off from the right side.
CAUTION
UPON REMOVING/REFITTING, PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES, DISCS
AND PADS.
CAUTION

AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER; OTHERWISE,
THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAK-
AGE.
To refit, carry out removal operations but in reverse order

SUSP - 211
Suspensions

Swing-arm

KEY:
1. Engine coupling link rod
2. Chassis coupling link rod
3. Silent-block
4. Chassis hinge pin
5. Link rod hinge pin
6. Engine hinge pin
7. Spacer
8. Link rod bushing
9. Resin bushing
10. Nut
11. Washer
12. Washer
13. Self-locking nut
14. Link rod bushing
15. Screw

Removal
WARNING
IT IS NOT NECESSARY TO REMOVE THE SWINGING ARM IN ORDER TO SERVICE IT.

SUSP - 212
Suspensions

- Rest the vehicle on its centre stand.


- Remove the lower cover.
- Remove the footrest.
- Support the engine firmly.
- Unscrew the pin connecting it to the engine and
collect the spacer.

- Operating from both sides of the vehicle, unscrew


the nut from the inside and collect the washer.

- Slide off the pin.

- Once the engine-side swinging arm has been re-


leased, do so with the chassis-side swinging arm,
working from both sides of the vehicle.
- Unscrew the nut and collect the washer.

SUSP - 213
Suspensions

- Slide off the pin connecting it to the chassis.

- Remove swinging arm by sliding it off towards the


front.

Overhaul
WARNING
CHECK SWINGING ARM CLEARANCES WITH THE ARM FITTED IN RIDING CONDITIONS.
- Remove the lower cover.
- Remove the footrest.
- Check axial clearance between both swinging
arms using a thickness gauge.
- If values non-conforming with those specified are
measured, remove the arm and replace the Teflon
spacer bushings.

Characteristic
Axial clearance between both swinging arms
Min: 0.6 ; Max: 1.2 mm

SUSP - 214
Suspensions

- Check clearances on the connection between the


chassis-side arm and the chassis using a thick-
ness gauge.
- If values non-conforming with those specified are
measured, remove the arm and replace the Teflon
spacer bushings.

Characteristic
Clearance between bushing and plates
Min: 0.6 ; Max: 1.2 mm

- In order to check silent-blocks, unscrew the nut


from inside, undo the screw and remove the silent-
block.
- Check that they are not broken. Otherwise, re-
place them.

- In order to remove the roller casings, remove the Teflon spacer bushing and the internal spacer A.
- Use a suitable plug to remove the roller casings B.
- Using a specific tool, drive the new roller casings being careful to position the bearings with the sealing
rings facing outwards.
- Once the ball bearing cages have been fitted, lubricate them with the recommended product.

Specific tooling
020115Y 18 punch
020244Y 15 punch
Recommended products
AGIP GREASE PV2 Grease for steering bearings, pin seats and swinging arm
White anhydrous-calcium based protective grease for roller bearings; temperature range between -20
C and +120 C NLGI 2; ISO-L-XBCIB2.

SUSP - 215
Suspensions

Refitting

- Follow the removal steps but in reverse order.


- Tighten to the prescribed torque.

LINK ROD
Name Torque in Nm
Connecting rod to chassis retainer 6020%
Connecting rod to engine retainer 4020%
Chassis connecting rod on engine connecting rod retainer 6020%
Silent-block on chassis retainer 5020%

Shock absorbers

Removal

Unscrew the upper nut and remove the


screw.

SUSP - 216
Suspensions

Lower the shock absorber.

Unscrew and remove the nut 1.


Slide off the right shock absorber.

Unscrew and remove the nut 2 and


collect the washer.
Remove the screw 3.
Slide off the left shock absorber.

To refit, carry out removal operations but in reverse order

Centre-stand

Remove the two springs indicated.

Undo the indicated screw and slide off


the U-bolt fixing screw.

SUSP - 217
Suspensions

To refit, carry out removal operations but in reverse order

SUSP - 218
INDEX OF TOPICS

BRAKING SYSTEM BRAK SYS


Braking system

KEY:
1. Front brake lever pipe, front brake calliper
2. Front brake pump /fluid reservoir
3. Front brake control lever
4. Rear brake pump/reservoir
5. Rear brake control lever
6. Rear brake calliper
7. Rear brake pads
8. Rear brake lever pipe, rear brake calliper
9. Front brake calliper
10. Front brake pads

Rear brake calliper

BRAK SYS - 220


Braking system

Removal

Undo the two screws indicated and re-


move the brake calliper.

If you want to replace the calliper, undo


the coupling screw from the pipe to the
calliper.

To refit, carry out removal operations but in reverse order

Locking torques (N*m)


Calliper on muffler plate retainer 2520%

Front brake calliper

Removal

Undo the two screws indicated and re-


move the brake calliper.

BRAK SYS - 221


Braking system

If you want to replace the calliper, undo


the coupling screw from the pipe to the
calliper.

To refit, carry out removal operations but in reverse order

Locking torques (N*m)


Calliper on fork retainer 2520%

Rear brake disc

Removal

Remove the rear wheel.


Undo and remove the five brake disc
screws.
Remove the brake disc.
CAUTION
UPON REFITTING, APPLY THE RECOMMENDED PROD-
UCT ON THE THREADING OF THE BRAKE DISC SCREWS.

Recommended products
LOCTITE 243 Loctite adhesive to assembly
cylindrical pieces
Loctite adhesive to assembly cylindrical pieces

Disc Inspection

Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated.
Check the brake disc for wear by measuring the minimum thickness with a micrometer at
different points. Replace the disc if the minimum thickness, even at a single point of the disc,
is less than the minimum value.
CAUTION
OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL.
Characteristic
Minimum value for brake disc thickness:
3.6 mm

BRAK SYS - 222


Braking system

Using a dial gauge, check that disc os-


cillation does not exceed the tolerance;
otherwise, replace it.

Characteristic
Brake disc oscillation tolerance:
0.3 mm

Front brake disc

Removal

Remove the front wheel.


Undo and remove the five brake disc
screws.
Remove the brake disc.
NOTE
SCREW ALL THE SCREWS MANUALLY AND TIGHTEN
THEM OPERATING DIAGONALLY
CAUTION
UPON REFITTING, APPLY THE RECOMMENDED PROD-
UCT ON THE THREADING OF THE BRAKE DISC SCREWS.

Recommended products
LOCTITE 243 Loctite adhesive to assembly
cylindrical pieces
Loctite adhesive to assembly cylindrical pieces

Disc Inspection

Carry out a visual inspection of brake disc surface. Replace the disc if scored or deteriorated.
Check the brake disc for wear by measuring the minimum thickness with a micrometer at
different points. Replace the disc if the minimum thickness, even at a single point of the disc,
is less than the minimum value.
CAUTION
OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL.
Characteristic
Minimum value for brake disc thickness:
3.6 mm

BRAK SYS - 223


Braking system

Using a dial gauge, check that disc os-


cillation does not exceed the tolerance;
otherwise, replace it.

Characteristic
Brake disc oscillation tolerance:
0.3 mm

Front brake pads

Removal

Remove the front brake calliper.

Loosen and slide off both pins.

Slide off the brake pads.

CAUTION

AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER; OTHERWISE,
THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAK-
AGE.

BRAK SYS - 224


Braking system

Check friction material for appropriate


thickness. If thinner than the minimum
value, replace it.

Characteristic
Friction material minimum thickness
1.5

In case of uneven wear, replace the


brake pads when the friction material
thickness difference is 0.5 mm
CAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY


ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

Refitting
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED.
INSIDE THE CALLIPER. UPON REFITTING, DO NOT INVERT THE POSITION OF THE LOCK.
For refitting, follow the operations in reverse order observing the tightening torque.

Rear brake pads

Removal

Remove the Seeger ring.

BRAK SYS - 225


Braking system

Slide off the pin.

Remove the spring.


CAUTION
THE ARROW STAMPED ON THE SPRING MUST ALWAYS
BE TURNED IN THE RIDING DIRECTION.

Slide off the brake pads.

Check friction material for appropriate


thickness. If thinner than the minimum
value, replace it.

Characteristic
Friction material minimum thickness
1.5

BRAK SYS - 226


Braking system

In case of uneven wear, replace the


brake pads when the friction material
thickness difference is 0.5 mm
CAUTION

ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY


ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.

Refitting
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED.
INSIDE THE CALLIPER. UPON REFITTING, DO NOT INVERT THE POSITION OF THE LOCK.
For refitting, follow the operations in reverse order observing the tightening torque.

Fill - Bleeding the braking system

Rear - combined

REAR BRAKE
Remove the rubber protection cover of
the bleed valve 4.
Insert a transparent plastic pipe in the
bleed valve 4 of the rear brake cal-
liper and insert the other end of this
pipe into a container to collect the fluid.
Quickly press and release the rear
brake lever several times and then
keep it fully pressed.
Loosen the bleed valve 1/4 of a turn so
that the brake fluid flows into the con-
tainer. This will release tension on the
brake lever and will make it go to the
end of stroke.
Repeat the operation until the fluid
draining into the container is air-bubble
free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE
RESERVOIR WITH THE NECESSARY QUANTITY OF

BRAK SYS - 227


Braking system

BRAKE FLUID. CHECK THAT, DURING THE OPERATION,


THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.

Tighten the bleed valve and remove the pipe.


Top-up the reservoir until the correct brake fluid level is obtained.
Refit the rubber protection cover.

Front

Remove the rubber protection cover of


the bleed valve 1.
Insert a transparent plastic pipe in the
bleed valve 1 of the front brake cal-
liper and insert the other end of this
pipe into a container to collect the fluid.
Quickly press and release the brake
lever of the specific brake calliper sev-
eral times, keeping it completely oper-
ated afterwards.

Loosen the bleed valve 1 of a turn so that the brake fluid flows into the container. This
will release tension on the brake lever and will make it go to the end of stroke.
Repeat the operation until the fluid draining into the container is completely free of air bub-
bles.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY
QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS
BRAKE FLUID IN THE RESERVOIR.
Tighten the bleed valve 1 and remove the pipe.
Top up restoring the correct front brake fluid level in the reservoir.
Refit the rubber protection cover.

BRAK SYS - 228


INDEX OF TOPICS

COOLING SYSTEM COOL SYS


Cooling system

Circuit diagram

KEY:
1. Expansion tank with cap;
2. Radiator / fitting pipe;
3. Radiator fitting / pump pipe;
4. Clamp;
5. Breather pipe;
6. White clic clamps;
7. White clic clamp;
8. Expansion tank cap;
9. Clip;
10. TBEI flanged screw;
11. To the water pump;
12. From the head;
13. Fitting / head sleeve;
14. Fitting;
15. Electric fan connector;
16. Electric fan

COOL SYS - 230


Cooling system

Electric fan check

Key:
1. Battery
2. Main fuses
3. Fan switch
4. Fan

ELECTRIC FAN OPERATION CHECK


To check the electric fan operation:

Remove the legshield.


Disconnect the thermal switch connec-
tor 2 and jump it.
The electric fan should switch on.

COOL SYS - 231


Cooling system

Undo and remove the screw 1 fixing


the radiator.

Locking torques (N*m)


M6 fixing screw for radiator (on plastic) 6 (4.44
ftlb)

Detach and lift the radiator to release it


from its seat.
Check the connection of connector
3.
Rotate the fan manually and check that
the blades do not touch the support.

If the rotation is free of obstacles:

Check the battery charge system and


the main fuse.

Thermal switch operation check

Remove the footrest.


Remove the thermal switch 1
Connect a pocket tester 2 (ohmme-
ter function) to the thermal switch 1
as shown in the picture.
Immerse the thermal switch in a con-
tainer 3 with coolant.
In the same container, immerse a ther-
mometer 4 ranging from 0 150C
(32 302F).
Place the container on a cooker 5
and heat the fluid slowly.
Check that the temperature indicated
in the thermometer and the value of the
thermal switch indicated in the tester
correspond to the data stated in the
chart.

COOL SYS - 232


Cooling system

COOLANT TEMPERATURE C (F) / RESISTANCE VALUES (OHM)


Specification Desc./Quantity
below 90 (194) Infinite
Above 90 (194) 0

Coolant replacement

In order to facilitate draining off the cooling system,


follow these steps:

Remove the front central cover.


Undo and remove the expansion tank
cap.
NOTE
BEFORE EMPTYING THE COOLING SYSTEM, PREPARE A
COLLECTING CONTAINER OF A MINIMUM CAPACITY OF
1.8 LITRES (0.39 GAL).

Loosen the clamp and remove the ra-


diator-pump pipe and allow the coolant
to drain into the collecting container.

Thermostat

COOL SYS - 233


Cooling system

Check

Key:
1.Instrument panel
2.Thermistor
3.Auxiliary fuses
4.Key switch
5.Battery
6.Main fuses

Thermistor operation check

Remove the thermistor 2.


Connect a pocket tester 10 (ohm-
meter function) to the thermistor 2 as
shown in the figure.
Immerse the thermistor in a container
11 with oil.
In the same container, immerse a ther-
mometer 12 ranging from 0 + 150
C (32 + 302F).
Place the container on a cooker 13
and heat the fluid slowly.

COOL SYS - 234


Cooling system

Check the temperature indicated in the


thermometer and the value of the ther-
mistor indicated in the tester.

Check that the thermistor varies according to the


temperature as indicated.

OIL TEMPERATURE C (F) / RESISTANCE VALUE OHM


Specification Desc./Quantity
50 (122F) approximately 226 34
85 (185F) approximately 64 7
CAUTION
REPLACE THE THERMISTOR IF VALUES DO NOT VARY OR DIFFER WIDELY FROM THE ONES
INDICATED ON THE CHART.

COOL SYS - 235


INDEX OF TOPICS

CHASSIS CHAS
Chassis

Seat

Undo and remove the four screws.


Remove the saddle.

Rear rack

Lift the saddle.


Undo and remove the four screws.

Slide off the screw cover cap.


Undo and remove the screw.
Remove the luggage rack.

CHAS - 237
Chassis

Driving mirrors

Loosen the nut indicated.


CAUTION
THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK-
WISE.

Rear handlebar cover

Remove the front handlebar cover.


Undo the two screws indicated.
Disconnect the connector powering
the instrument panel.

Instrument panel

Remove the front handlebar cover.


Undo the two screws indicated.
Disconnect the connector powering
the instrument panel.

Front handlebar cover

CHAS - 238
Chassis

Undo the two screws indicated.

Operating from both sides of the vehi-


cle, undo the two screws indicated.

Operating on both sides of the vehicle,


undo the screw indicated.

Frame central cover

Lift the saddle.


Undo and remove the two screws.

CHAS - 239
Chassis

Undo and remove the two screws.

Remove the central inspection cover


by sliding it off its hooks.

Legshield

Operating on both sides, undo and re-


move the screw.

Remove the front case by sliding it off


its hooks, being careful with the
tongues and related fitting slots.

CHAS - 240
Chassis

Remove the front mudguard.


Remove the front wheel.
Operating from both sides, undo and
remove the five screws.
CAUTION
PLACE A SUPPORT UNDER THE CHASSIS SO THAT THE
FRONT WHEEL DOES NOT TOUCH
THE GROUND.

Operating from both sides, undo and


remove the three screws.

Undo and remove the two screws.

Move the external legshield forwards


and disconnect front headlamp con-
nector.

CHAS - 241
Chassis

Operating from both sides, undo the


two screws and remove the front turn
indicators from the back.

Slide the external front shield off the front fork.

Knee-guard

Remove the front central cover.


Operating from both sides, undo and
remove the screw.

Remove the handlebar cover.


Undo and remove the two screws.
Slide off the bag hook.

CHAS - 242
Chassis

Insert the key in the glove-box lock,


turn it clockwise and open the com-
partment.
Undo and remove the four screws.

Close the glove-box.


Operating from both sides, undo and
remove the four side screws.

Disconnect the auxiliary plug socket in


the glove-box.
By making the handlebar rotate, pull
forwards the internal legshield off the
hooks being careful with the fitting
slots.

Footrest

Remove the central inspection cover.


Remove both side fairings.
Operating on both sides, undo and re-
move the rear screw of the footrest.

CHAS - 243
Chassis

Operating on both sides, undo and re-


move the two screws of the footrest.

Remove the battery.


Unscrew and remove the bolt inside
the battery compartment.
Operating from both sides, undo and
remove the lower screw fixing it to the
internal legshield.
Remove the footrest being careful with
the tongues and the related fitting slots.

Passenger footrest removal

In riding position, rotate the passenger


footrest 1.
Lift the footrest upper rubber edge 3.
Slide and remove the pin 4.
Remove the passenger footrest 1.
NOTE
THESE OPERATIONS REFER TO ONLY ONE PASSENGER
FOOTREST BUT THEY APPLY TO BOTH.
NOTE
THIS OPERATION IS NECESSARY ONLY TO REMOVE THE
METAL PART OF THE FOOTREST. TO REMOVE FAIR-
INGS, JUST REMOVE THE PASSENGER FOOTREST RUB-
BER.

CHAS - 244
Chassis

Side fairings

Left and right fairings removal

Remove the rear central cover.


Undo and remove the screw.

Undo the two screws and remove the


passenger footrest rubber.

Undo and remove the screw.

Push aside the tail section.


Remove the fairing by sliding it off the
hooks, being careful with the tongues
and related fitting slots.

CHAS - 245
Chassis

Air filter

Remove the left side fairing.


Remove the helmet compartment.
Loosen the intake manifold clamp.
Slide off the intake manifold.

Undo the two screws fixing the filter


casing.

Remove the clamp fastening the gas


recovery pipe to the cylinder head cov-
er.
Remove the filter casing.

Tail guard

Remove the rear central cover.


Remove the luggage rack.
Operating on both sides, undo and re-
move the four.

CHAS - 246
Chassis

Undo and remove the two screws in-


side the helmet compartment.

Operating on both sides, undo and re-


move the screw.

Undo and remove the three fixing


screws.

CHAS - 247
Chassis

Remove the tail section from it fittings


with the side fairings.
Move the tail section backwards and
disconnect the rear light connector.

Undo the two fixing screws and remove


the seat lock.
Remove the tail section by sliding it
backwards.

Undo the two screws indicated and re-


move the tail section clamp.

Rear mudguard

Undo and remove the three screws.

CHAS - 248
Chassis

Undo the three screws and remove li-


cense plate.

Undo and remove the screw.

Undo and remove the screws indica-


ted.

Undo the screw and slide off the li-


cense plate light backwards.

CHAS - 249
Chassis

Disconnect the license plate light con-


nector.

Remove the rear mudguard.

Should the rear mudguard holder frame be re-


moved before taking out the rear mudguard pro-
ceed as follows:

Undo and remove the two screws.

Helmet bay

Remove the saddle


Remove the luggage rack.
Remove the tail section.
Undo the two screws indicated.

CHAS - 250
Chassis

Working on both sides of the vehicle,


undo the screw indicated and collect
the washer.
Remove the helmet compartment.

Front mudguard

Operating from both sides, undo and


remove the two screws.

Slide off the front mudguard forwards.

Fuel tank

Remove the saddle


Remove the luggage rack.
Remove the tail section.
Remove the helmet compartment.
Disconnect the fuel level sensor power
connector.
Release the tank from the fuel pipes.

CHAS - 251
Chassis

Undo the two screws indicated.

Radiator fan

Drain off the system.


Remove the shield back plate.
Remove the legshield.
Disconnect the electric fan connector.

Disconnect the two thermal switch con-


nectors.

Loosen the clamps and remove the


three pipes.

CHAS - 252
Chassis

Undo and remove the screw.


Slide off the radiator upwards.

Expansion tank

Drain off the cooling system:

Remove the front central cover.


Remove the shield back plate.
Loosen and remove the clamp.

Loosen and remove the clamp.


NOTE
UPON REFITTING, REPLACE THE REMOVED CLAMPS
WITH NEW ONES.

CHAS - 253
Chassis

Operating from both sides, undo and


remove the screw.
Remove the expansion tank.

Lower cover

Undo and remove the rear screw.

Undo and remove the two side screws.

Undo and remove the two screws.

CHAS - 254
Chassis

Undo and remove the screw fixing it to


the legshield on the front wheel hous-
ing.
Undo and remove the screw.

Lift the footrest and slide the lower


shield off its hooks being careful with
the tongues and related fitting slots.

The lower shield can be split into right and left sec-
tions.
To do this, proceed as follows:

Undo and remove the two screws.


Slide off the lower shield to separate it
into a right and a left section.

CHAS - 255
INDEX OF TOPICS

PRE-DELIVERY PRE DE
Pre-delivery

Carry out the listed checks before delivering the vehicle.


WARNING

BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.

Aesthetic inspection

- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt

Tightening torques inspection

- Safety locks:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws

Electrical system

- Main switch
- Headlamps: high-beam lights, low-beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric start-up
- Engine stop via emergency stop switch and side stand
- Saddle electric opening switch (if present)

PRE DE - 257
Pre-delivery

- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.


INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION

UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-


TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR AP-
PROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.

Levels check
- Hydraulic braking system fluid level
- Rear hub oil level
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)

Road test
- Cold start
- Instrument panel operation
- Response to throttle control
- Stability when accelerating and braking

PRE DE - 258
Pre-delivery

- Front and rear brake efficiency


- Front and rear suspension efficiency
- Abnormal noise

Static test

Static check after test drive:


- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)

Functional inspection

- Hydraulic braking system


- Brake levers stroke
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories

NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.


CAUTION

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

PRE DE - 259

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