Vespa PX 125 150 Euro2 (EN)
Vespa PX 125 150 Euro2 (EN)
Vespa PX 125 150 Euro2 (EN)
633241
WORKSHOP MANUAL
WORKSHOP MANUAL
Vespa PX 125 150 Euro 2
This manual has been prepared by Piaggio & C. S.p.A, for use in the workshops of authorized Piaggio-Gilera dealers and subagents. It is assumed that the person utilizing this manual for servicing or repairing Piaggio vehicles has knowledge of the principles of mechanics and standard procedures required for general vehicle repair. Any relevant changes concerning the vehicle characteristics or specific repair operations will be divulged in the form of updates to this manual. Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer to the pages of this manual concerning specific tools and equipment and the special tools catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS TOOLING MAINTENANCE ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS BRAKING SYSTEM CHASSIS PRE-DELIVERY TIME
CHAR TOOL MAIN ELE SYS ENG VE ENG SUSP BRAK SYS CHAS PRE DE TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.
Vehicle identification
VEHICLE IDENTIFICATION
Specification Frame prefix (125) Engine prefix (125) Frame prefix (150) Desc./Quantity VNX2T VNX1M VLX1T
CHAR - 7
Characteristics
Desc./Quantity VLX1M
Engine
ENGINE
Specification Engine type Desc./Quantity 2-stroke with rotary intake timing
CHAR - 8
Characteristics
Specification No. of cylinders Bore and stroke (125) Bore and stroke (150) Displacement (125) Displacement (150) Compression ratio (125) Compression ratio (150) Carburettor Engine idle speed CO value Air filter Starting system Lubrication Fuel supply Clutch Cooling Max power output (shaft) 125cc Max power output (shaft) 150cc Max speed (125) Max speed (150)
Desc./Quantity 1 52,2 x 57 mm 58 x 57 mm 123,4 Cm3 150,599 Cm3 8:1 8:1 Dell'orto SI 20/20 D 1900 100 rpm 3,8 0,5% Metallic net soaked in oil-petrol mixture Electric starter motor and kick-start Mixture oil Oil-petrol mixture through carburettor with automatic mixer (mass flow varying with engine speed) and throttle valve Multi-disc. Forced air by a centrifugal fan. 6 Kw (8 hp) at 5600 rpm 6.6 Kw (9 hp) at 5,700 rpm 80,7 Km/h 82,8 Km/h
Transmission
TRANSMISSION
Specification Gear-box Desc./Quantity 4-speed with constantly engaged gears
Capacities
CAPACITIES
Specification Gear-box Mixer oil tank Fuel tank Desc./Quantity ~ 250 cc. ~1.6 litres (including 0.4 l reserve) ~8 litres (including ~2.1 l reserve)
Electrical system
ELECTRICAL SYSTEM
1 2 3 4 5 6 Specification Ignition type Spark advance (T.D.C.) Spark plug Battery Fuse Generator Desc./Quantity Electronic ignition by capacitive discharge with H.T. coil 18 1 CHAMPION RL82C 12V - 9Ah 7.5 A AC
Frame
CHAR - 9
Characteristics
Brakes
BRAKES
Specification Front Rear Desc./Quantity 220 mm disc hydraulically operated via lever mounted on RHS of handlebars 140 mm drum with expanding shoes mechanically activated via pedal on RHS of footrest
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES
150cc Version
CHAR - 10
Characteristics
Dell'Orto
CARBURETTOR
Specification Type Diffuser diameter Main jet Slow running jet Main air jet Throttle valve (type) Emulsifier (code) Sprayer Starter jet Air idling screw Desc./Quantity SI20/20D 20 mm 98 45/160 150 6823.16.64 BE5 280/100 60/100 1 3/4
Tightening Torques
STEERING UNIT
Name Upper steering ring nut Top steering housing Handlebar fixing screw* Torque in Nm 56 67 (hence loosen by 80 - 90) 3044
FRAME
Name Engine - frame bolt * Rim - hub fixing nuts (front-rear) Shock-absorber - frame fixing nut* Shock-absorber - engine bolt* Rear wheel axle* Torque in Nm 61 75 20 27 3040 13 23 7590
FRONT SUSPENSION
Name Shock-absorber mounting plate - steering column fixing nuts Upper shock-absorber fixing nut Lower shock-absorber fixing nut Front wheel axle nut* Torque in Nm 2027 3040 2027 60100
FRONT BRAKE
Name Reservoir - pipe fitting Pipe - calliper fitting Intermediate pipe fitting Calliper fixing screw* Disc fixing screw* Oil draining screw Torque in Nm 812 1525 1015 2025 56 1012
ENGINE
Name Coils mounting bracket fixing screw Kick-start lever fixing nut Clutch assy. fixing nut Multi-gear pinion nut Flywheel fixing nut Carburettor fixing bolts Clutch cover fixing screws Cylinder head fixing nuts Spark plug Crankcase mating screws Torque in Nm 34 2326 40 45 30 35 60 65 1620 68 1318 2025 1113
CHAR - 11
Characteristics
Name Wheel axle nut Gear shifter nuts Starter motor screws Fan cover screws Air-box fixing screws Gear fixing nut Mixer fixing screws Head fixing nuts Gear-box trunnion N.B.
* Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE ASSEMBLY. NOTICE OF TECHNICAL SERVICING Tightening torque - riding mirror This is to inform you that a standard tightening torque has been introduced for the riding mirror fixing screw: 20 - 25 Nm.
CHAR - 12
Characteristics
CHAR - 13
Characteristics
CHAR - 14
Characteristics
Initials G
Cylinder 58,420
Piston 58,180
Piston rings
CHAR - 15
Characteristics
CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE E BETWEEN BIG END AND HALF CRANKSHAFT ON FLYWHEEL-SIDE
Name Connecting Rod Washer (2) Half-crankshaft clutchside Half-crankshaft flywheel-side Spacer tool Description Dimensions A= 15,4 +0 -0,05 G= 0,5 +0,05 -0,03 C= 11,1 -0 +0,05 D= 11,1 -0 +0,05 H= 38,95 Initials E E E E Quantity 0,15 0,46 0,15 0,46 0,15 0,46 0,15 0,46
CONNECTING ROD - CRANKSHAFT. ASSEMBLY CLEARANCE F BETWEEN BIG END ROLLER CAGE AND HALF CRANKSHAFT ON FLYWHEEL-SIDE
Name Connecting Rod Washer (2) Half-crankshaft clutchside Half-crankshaft flywheel-side Spacer tool Description Dimensions B= 15,6 -0,1 -0,2 G= 0,5 +0,05 -0,03 C= 11,1 -0 +0,05 D= 11,1 -0 +0,05 H= 38,95 Initials F F F F Quantity 0,05 0,41 0,05 0,41 0,05 0,41 0,05 0,41
Connecting rods and roller cages are subdivided into 4 categories (indicated by markings on big end and outer cage rim, respectively) Mate connecting rod with cage of same category; if such assembly results to be excessively noisy, use a roller cage from next category. For the wrist pin, fitted with 0 clearance, the maximum allowable play after use must be 0.02 mm.
CHAR - 16
Characteristics
The maximum allowable end-play for the connecting rod after use (intended as the longitudinal slide on the big end) is 0.7mm.
Gearbox shoulders
GEARBOX SHOULDERS
Name Shoulder Shoulder (1st oversize) Shoulder (2nd oversize) Shoulder (3rd oversize) Shoulder (4th oversize) N.B. Description Dimensions 2,05 +0 -0,06 2,20 +0 -0,06 2,35 +0 -0,06 2,50 +0 -0,06 2,65 +0 -0,06 Initials A A A A A Quantity 0,15 0,40 0,15 0,40 0,15 0,40 0,15 0,40 0,15 0,40
IF THE SPECIFIED CLEARANCE A CANNOT BE ACHIEVED, REPLACE THE SHOULDER RING WITH AN OVERSIZED ONE SUCH TO ALLOW OBTAINING THE PRESCRIBED PLAY. TO CHECK THE CLEARANCE, USE A FEELER GAUGE.
Products
TABLE OF RECOMMENDED PRODUCTS
Product AGIP GEAR 80W-90 AGIP CITY HI TEC 4T Specifications SAE 80W-90 oil complying with API GL4 specifications Oil to lubricate flexible transmissions Oil for 2-stroke engines: SAE 5W-40, API (brake, throttle control and mixer, odomSL, ACEA A3, JASO MA eter) Grease (brake level, throttle twistgrip, Calcium complex soap grease NLGI 2; gaer) ISO-L-XBCIB2 Mixer oil synthetic oil for 2-stroke engines: JASO FC, ISO-L-EGD Grease for odometer transmission gear Soap-based lithium grease with NLGI 3; case ISO-L-XBCHA3, DIN K3K-20 Brake fluid FMVSS DOT 4 Synthetic fluid Description gearbox oil
AGIP GP 330 AGIP CITY TEC 2T AGIP GREASE MU3 AGIP BRAKE 4
CHAR - 17
INDEX OF TOPICS
TOOLING
TOOL
Tooling
TOOLING
Stores code 020004Y Description Punch for removing fifth wheels from headstock
020055Y
020074Y
002850y
002973y
020320Y
TOOL - 19
Tooling
020329Y
020330Y
020331Y
Digital multimeter
020332Y
TOOL - 20
Tooling
020334Y
020335Y
001330Y
TOOL - 21
Tooling
020321y
006029Y
020625Y
001467Y021
TOOL - 22
Tooling
020150Y
020057Y
Calking tool
020095Y
008564Y
Flywheel extractor
008886Y
Crankshaft extractor
004499Y
TOOL - 23
Tooling
060007Y
060824Y
Inspection probe
008119Y009
001729Y
020322Y
TOOL - 24
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Maintenance chart
EVERY 2 YEARS
Action Brake fluid - change
AT 1000 KM OR 4 MONTHS
Action Gear-box oil level - replacement Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake fluid level - check Safety locks - check Electrical system and battery - check Tyre pressure and wear - check Vehicle and brake test - road test
AT 5000 KM OR 12 MONTHS
Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean
AT 10000 KM O 24 MONTHS
Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test (*) See regulations in section Idling speed adjustement
AT 15000 KM OR 36 MONTHS
Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing
MAIN - 26
Maintenance
Action Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean
AT 20000 KM
Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Cylinder cooling system - check/cleaning Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean (*) See regulations in section Idling speed adjustement
AT 25000 KM
Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean
AT 30000 KM
Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake pads - check condition and wear Flexible brake lines - Change Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test
MAIN - 27
Maintenance
AT 35000 KM
Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean
AT 40000 KM
Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Cylinder cooling system - check/cleaning Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean (*) See regulations in section Idling speed adjustement
AT 45000 KM
Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean
AT 50000 KM
Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake pads - check condition and wear
MAIN - 28
Maintenance
Action Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test (*) See regulations in section Idling speed adjustement
AT 55000 KM
Action Gear-box oil level - check Spark plug - replacement Air filter on carburetor - Clean Transmission gas mixer- adjust Brake and clutch lever - greasing Brake pads - check condition and wear Brake fluid level - check Electrical system and battery - check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean
AT 60000 KM
Action Gear-box oil level - replacement Spark plug - replacement Air filter on carburetor - Clean Idle speed (*) - adjustment Cylinder cooling system - check/cleaning Transmission gas mixer- adjust Odometer gear - greasing Steering - adjustment Brake and clutch lever - greasing Brake pads - check condition and wear Flexible brake lines - Change Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment check Tyres condition and wear - Check Vehicle and brake test - road test Secondary air filter (external / internal) - Clean (*) See regulations in section Idling speed adjustement
MAIN - 29
Maintenance
Carburettor
Disassemble the carburettor and clean all components with solvent, hence dry with compressed air all ducts, in order to ensure proper cleaning. Carefully check the state of each component. The throttle valve must be free to slide inside the mixture chamber; replace if excessive play is found. If the mixture chamber is excessively worn, such to prevent the sliding of the throttle valve (although new), replace the carburettor. All seals should be replaced upon reassembly.
CARBURETTOR
Specification Conical needle Float Emulsifier air adjusting screw Emulsifier Main jet Slow-running jet Fuel flow adjusting screw Throttle valve adjusting screw Throttle valve Starter jet Choke device Desc./Quantity
Maintenance
In the impossibility of obtaining the specified values, or if the engine is found to be running rough, proceed by replacing defective components.
Specific tooling
020330Y Stroboscopic light to check timing 020332Y Digital rev counter
Spark plug
Detach the spark plug cap Carefully inspect the spark plug and replace it if the insulator is damaged Using a feeler gauge, measure the spark gap, and adjust it if necessary Ensure the sealing washer is in good state Refit the spark plug by screwing it in by hand, and tightening it at the prescribed torque using a box spanner
Electric characteristic
Spark plug CHAMPION RL82C Spark gap 0,5 0,6 mm
Air filter
Remove the engine cowling and the air-box cover by loosening the four fixing screws shown in the figure and the idle adjusting screw; hence release the filter. Clean the filter with 50% fuel-oil mixture, hence dry it with compressed air.
Recommended products
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO FC, ISOL-EGD
MAIN - 31
Maintenance
Headlight adjustment
Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen; 2. Turn on the headlight and check that the borderline of the projected light beam on the screen is not lower than 9/10 of the distance from the ground to the centre of vehicle headlamp and higher than 7/10; 3. If otherwise, adjust the right headlight with screw A.
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.
CO check
The test must be carried out after carefully cleaning all carburettor components and air filter, and with the spark plug in good conditions. Warm up the engine by riding the vehicle for at least ten minutes Switch off the engine Remove the 2 secondary air box screws shown in the figure Place a plastic sheet between the one-way valve and the aluminium outlet as shown in the figure
MAIN - 32
Maintenance
Ensure the one-way valve packing properly seals the aluminium outlet fitting. Refit the aluminium outlet onto the SAS box as shown in the picture.
Remove the gas outlet cap, shown in the figure, on the exhaust.
Attach the special tool and orientate the connectors as shown in the figure. Start the engine, adjust the idle speed to 1,300 100 rpm and check the CO readings are equal to 41% with the idle air adjusting screw opened by 2+ turns. If the parameters here specified cannot be met, try adjusting the idle air adjusting screw. Otherwise, check the choke device.
Specific tooling
020320Y Exhaust gases analyser 020332Y Digital rev counter 020625Y Kit for sampling gas from the exhaust manifold
MAIN - 33
Maintenance
Remove the sponge and wash it with soap and water. Dry it with compressed air before refitting.
Gearbox Oil
Check for the presence of oil inside the gearbox (oil capacity ~250 g); with the vehicle axis perfectly vertical, the oil level must be at the height of inspection hole A. To replace the oil, drain the box using filler hole B. Pour some fresh oil and let the engine run for a few seconds, hence drain the box again. Pour 250 g of fresh oil through hole A, so that the level reaches the reference height.
Recommended products
AGIP GEAR 80W-90 gearbox oil SAE 80W-90 oil complying with API GL4 specifications
MAIN - 34
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
ELECTRICAL SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Specification Front LHS turn signal light Key switch Enable button Indicators switch Front headlight Instrument panel lighting bulb Turn signal warning light Reserve fuel light Headlamp warning light High-beam warning light Instrument panel Headlight switch Start up button Horn Stop light switch (front brake) Desc./Quantity
ELE SYS - 36
Electrical system
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Specification Front RHS turn signal light Rear brake stop button Anti-repeating device Fuel level sender Magneto flywheel Electronic ignition device Rear RHS turn signal light Starter motor Taillight Starter relay Rear LHS turn signal light Battery Fuse box Voltage regulator Turn signals master-box
Desc./Quantity
12V - 9Ah
Components arrangement
ELE SYS - 37
Electrical system
COMPONENTS ARRANGEMENT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Specification Key switch Voltage regulator Electronic Control Unit (C.D.I.) with H.T coil Battery Starter motor Magneto flywheel Anti-repeating device Spark plug Remote starter switch Fuse Horn Turn signals master-box Front headlight Front turn signal lights Taillight Rear turn signal lights Desc./Quantity
12V - 9Ah
7.5 A
IGNITION
1 2 3 4 Specification Magneto flywheel Key switch contacts Electronic Control Unit (C.D.I.) with H.T coil Spark plug Desc./Quantity
ELE SYS - 38
Electrical system
LIGHTS
1 2 3 4 5 6 7 8 9 10 Specification Voltage regulator Magneto flywheel Key switch contacts Headlight bulb High-beam warning light Light switch Headlight switch Rear side light bulb Front side light bulb Headlamp warning light Desc./Quantity
ELE SYS - 39
Electrical system
7.5 A
12V - 9Ah
ELE SYS - 40
Electrical system
12V-1,2W 12V-10W
ELE SYS - 41
Electrical system
ELE SYS - 42
Electrical system
ELE SYS - 43
Electrical system
IGNITION CIRCUIT
1 2 3 4 Specification WHITE RED GREEN GREEN Desc./Quantity
Stator check
In the event of a malfunctioning of the ignition system, with no evident cause, it will be necessary to replace the ECU. Remember that all wires can only be detached with the engine off. If the ignition system is found to be working properly once the new ECU has been fitted, then the cause of the problem is obviously to be attributed to a defective CDI device. In the event that the ignition system is still malfunctioning, it will be necessary to check the generator and the stator components, as follows: After an eye inspection of the connections, perform measurements on recharge coil and pick-up (see table) using the specified tester. If such readings do not match the stated values, proceed by replacing the stator and its components.
Specific tooling
020331Y Digital multimeter
STATOR CHECK
1 2 Specification RED - WHITE wire GREEN - WHITE wire Desc./Quantity 90 140 ohm 800 1100 ohm
ELE SYS - 44
Electrical system
ELE SYS - 45
Electrical system
4) Battery recharge faulty (regulator open-circuited). Interventions FAULT 3 Replace the regulator, as certainly faulty, and the fuse. FAULT 4 a) Attach an ammeter between the voltage regulator and the battery, and check that, at 3,000 rpm and with the battery at 13V, the current supplied is approximately 1.5 to 2 A. If the measured values are below this limit, then replace the voltage regulator. b) If replacing the regulator does not solve the problem, check, using the recommended tester, for peaks in the alternate currents between the yellow wire connection and the red wire departing from the positive battery pole. The voltage supplied by the generator must be between 26 and 30V, at 3,000 rpm (this measurement must obviously be carried out with the battery disconnected).
Specific tooling
020331Y Digital multimeter
Starter motor
Bench tests to be performed on the electric starter motor 1) No-load test: the starter motor, unloaded, must absorb less than 10 A with a voltage supply > 11.7 V and must spin at more than 18,000 rpm. 2) Load test: load the starter motor so that the absorbed current is equal to 40 A, and the supplied voltage is 10 V. In such conditions, the output torque provided must 0.014 Nm, at a speed of no less than 10,000 rpm. 3) Breakaway test: with the rotor restrained and supplied voltage of 7 V, the absorbed current must not be higher than 100 A and the torque not less than 0.033 Nm.
N.B.
ALL THESE CHARACTERISTICS MUST BE MEASURED WITH CHARGED BATTERY AND AFTER RUNNING THE MOTOR FOR 30" IN THE CONDITIONS STATED IN 1.
ELE SYS - 46
Electrical system
STARTER MOTOR
1 2 3 4 5 6 Specification Nominal voltage Nominal power Direction of rotation Engine connection Control Battery Desc./Quantity 12V 0,15 kW Clockwise Via pinion and gear ring on crankshaft, transmission-side Pushbutton 12V - 9Ah
Fuses
The starter system and horn are protected by a 7.5A fuse, A, located on the LHS of the battery tray. Before replacing a burst fuse, it is necessary to find the cause of the failure. Never attempt to close the circuit with any material other than the fuse.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE). CAUTION
ELE SYS - 47
Electrical system
ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE.
Dry-charge battery
COMMISSIONING A NEW DRY-CHARGED BATTERY - Remove the battery air pipe stop cap and each single cell cap. - Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 B) with an ambient temperature not below 15C, until it reaches the upper level indicated on the block. - Tilt the battery slightly to remove any air bubbles formed during filling. - Place the caps on each single cell filling hole without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases. - Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes). - Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water; - Before 24 hours elapse, recharge the battery following these steps: - Connect the battery charger terminals observing the correct polarity; - Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity; - Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge. - Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester. - If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging. - Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle. - If the voltage indicated is low, charge the battery another 4-6 hours in the way described above. Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart; otherwise, recharge the battery again in the same way indicated above.
ELE SYS - 48
INDEX OF TOPICS
ENG VE
ENG VE - 50
Remove the rear shock-absorber fixing nut and hence the bolt. For the reassembly, follow the above operations in reverse order, using the prescribed tightening torques.
CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD. WARNING Wear safety goggles when using hitting tools. WARNING Be very careful when handling fuel.
ENG VE - 51
INDEX OF TOPICS
ENGINE
ENG
Engine
Remove the fixing screws shown and hence detach the volute and the gear shifter cover. Remove the kick-start lever after having detached the lower fastener.
ENG - 53
Engine
With the aid of a hacksaw, abrade the pinion head ring. Using two screwdrivers, detach the cap.
Remove the retaining ring shown by the arrow in the figure and remove the pinion components.
WARNING THE PACKING ON THE MATING SURFACE MUST ALWAYS BE REPLACED WITH A NEW ONE, USING LOCTITE.
ENG - 54
Engine
Using pliers for internal split rings, remove the retaining ring shown. Lift the assembly by the end of the shaft and remove the shaft by hitting the housing with a mallet.
The removal of the bearing may be carried out by pushing in the direction shown in the figure. This will also result in the removal of the drive gear. In the event that the bearing remains on drive gear, use the special extractor. After heating the drive gear with the air heater, refit the drive shaft with all the components previously removed. Refit the remaining components following the above operations in the reverse order.
Specific tooling
001467Y Extractor for bearings for holes 001467Y021 Extraction pliers for 11 mm bearings 020151Y Air heater 020150Y Air heater support Position a new cap onto the pinion and round the edges using the special tool to safely lock the assembly in a vice. Rotate the assembly by a quarter turn and proceed by rounding the remaining section of the caps circumference.
Specific tooling
020057Y Calking tool
ENG - 55
Engine
After removing the rear cover, release the brush clips connected to the magnetic fields. Remove the brush plate. Detach the old brushes and weld a new set of brushes, hence replace the brush plate.
After removing the rear cover, detach the drive gear retaining pin and remove the gear. Refit the assembly components in the reverse order.
Specific tooling
020095Y Flywheel retaining tool
Remove the flywheel retaining tool. Extract the flywheel using the special extractor.
Specific tooling
008564Y Flywheel extractor
ENG - 56
Engine
Recommended products
AGIP GREASE PV2 Grease for steering bearings, bolt seatings for swinging arms and faying surface of driven pulley spring (only pulley side) Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2
ENG - 57
Engine
ENG - 58
Engine
Specific tooling
008886Y Crankshaft extractor
Using the special extractor, remove the roller bearing from the crankshaft.
Specific tooling
004499Y Camshaft bearing extractor
Using the special extractor, remove the roller bearing from the crankcase.
ENG - 59
Engine
Specific tooling
020151Y Air heater 020150Y Air heater support Heat up the crankcase, as already done for the clutch-side half-crankcase, focusing exclusively on the bearing housing. Position the bearing using a length of tube pushing directly on the bearing's outer ring.
Position the crankshaft onto the special support. Install the special spacer as shown in the figure and, using a length of tube of adequate diameter, push the bearing until the inner ring (heated up in oil at 120C) comes into contact with the spacer. Once the assembly is completed, remove the spacer.
Specific tooling
020265Y Bearing fitting base 060007Y Crankcase bearing spacer
ENG - 60
Engine
ENG - 61
Engine
CONCEPTUAL DIAGRAMS
Specification Fuel tank filler cap Oil tank filler cap Oil level gauge SEPARATE LUBRICATION device box Oil inlet hose Oil outlet hose Oil outlet valve A B Desc./Quantity
Oil pump
Remove the carburettor box. Remove the mixer drive shaft from its housing.
ENG - 62
Engine
Remove the 3 fixing screws and the mixer cover with the lever.
Remove the mixer fixing screw and then use pliers for internal split rings to remove the mixer body.
Refit the components following the removal procedure in the reverse order, paying attention in positioning the pump body correctly in its housing, so to be able to easily insert the retaining screw.
See also
Removing the carburettor
ENG - 63
Engine
After removing the air filter, loosen the two 8mm Allen screws and hence remove the carburettor.
ENG - 64
Engine
Remove the main and idle jets and blow with compressed air.
Remove the float pin to release the float, and hence the conical needle.
ENG - 65
Engine
From the side opposite to that shown in the figure and with the aid of a puncher, remove the conical pin and extract the gear shifting lever.
ENG - 66
Engine
Split the two half-crankcases. Using pliers for external split rings, remove the retaining ring and extract the gears.
Remove the multiple gear shaft using a mallet from the side opposite to that shown in the figure. Do not let the 21 rollers composing the bearing fall onto the ground.
ENG - 67
Engine
After removing the internal oil seal and the external dust cover, remove the bearing retaining ring through the use of internal split ring pliers. Extract the roller bearing using a flat head puncher from the side opposite to that shown in the figure.
After removing the retaining washer shown in the figure, remove the fastener underneath it, hence extract the even tension gear. Remove the rivet head and replace any faulty component. Refit the components using new rivets.
ENG - 68
Engine
Refit the trunnion A onto the gear shifter shaft B and tighten it to the prescribed torque (LHS thread). Prepare a tool D as shown in the figure and insert it into the groove machined on the shaft. Align the tool's protrusion C with the edge F of the bushing to be rounded. Using a hammer and a length of tube (internal diameter 17.5 mm), round the threaded end of the bushing on the trunnion.
Install the multiple gear onto its housing carefully positioning the 21 rollers, using the recommended grease to keep them in place during the reassembly. With the refitting operation concluded, tighten the shaft lock nut to the prescribed torque.
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
Specific tooling
060824Y Inspection probe
Characteristic
ENG - 69
Engine
Axial play 0,20 0,40 mm Using the special tool, proceed by removing the gear shaft.
Specific tooling
008119Y009 Tube to assemble shafts and axles
See also
Splitting the crankcase halves
Clutch
Remove the 3 fixing screws and the clutch cover.
ENG - 70
Engine
Restrain the clutch using the special tool, as shown in the figure, then remove the locknut and the clutch assembly.
CAUTION DURING THE OPERATIONS OF REMOVAL, DO NOT LET THE WOODRUFF KEY FALL INSIDE THE ENGINE.
Specific tooling
001729Y Clutch retaining tool Remove the mixer drive gear from its housing.
Specific tooling
020322Y Clutch removing/fitting tool
Check the conditions of all components and the camber of the metal discs. A camber smaller than the prescribed one may cause slippage. Refit the clutch assembly components inverting the order followed for the disassembly.
ENG - 71
Engine
Place the mixer drive gear with the rounded edge facing the crankcase bearing.
Refit the clutch assembly onto the engine and tighten the locknut using the special retainer. Refit the remaining components in following the procedures carried out from their removal in the reverse order.
Specific tooling
001729Y Clutch retaining tool
ENG - 72
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
After removing the split ring on the outer side of the wheel hub, and the seal ring, remove the bearing using a length of pipe of adequate diameter and a mallet, as shown in the figure. Follow the same procedure to remove the roller cage on the opposite side.
Handlebar Removal
Remove the 2 rear view mirrors and their fixing ring nuts. Remove the handlebar cover as described in the Bodywork chapter and the speedometer.
SUSP - 74
Suspensions
Refitting
Upon reassembly, tighten to the prescribed torque.
N.B. * Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE ASSEMBLY.
Specific tooling
020055Y Wrench for steering tube ring nut
Overhaul
To remove the bearing housings from the frame use the special tool shown in the figure.
Specific tooling
020004Y Punch for removing fifth wheels from headstock
SUSP - 75
Suspensions
Using the special tool remove the bearing and dust ring housings from the steering column as shown in the picture. Proceed with mallet hits.
Specific tooling
020004Y Punch for removing fifth wheels from headstock
Using the special tool, refit the dust ring and the bearing housing onto the steering column and push them as far as they go.
Specific tooling
006029Y Punch for fitting fifth wheel seat on steering tube
Servicing the front suspension-steering assembly, described below, deals mainly with replacing parts (pin- NADELLA roller bushings - sealing rings unit and dust guard) which connect the steering tube to the front wheel holder swinging hub.
N.B. BEFORE PROCEEDING WITH THE DESCRIBED SERVICE, CHECK THAT THE STEERING TUBE AND THE WHEEL HOLDER HUB ARE IN EXCELLENT CONDITIONS: ONLY THEN IS THE SERVICE JUSTIFIABLE. MOREOVER, REMEMBER THE STEERING TUBE SHOULD BE REPLACED WITH A NEW ONE WHEN DEFORMED.
a = 12 Punch b = Sharp-edged end Use a suitable punch with the dimensions indicated on the figure; hit with a mallet until the wedging washer is crushed and then extract it with the help of a pointed end. Repeat the operation for the second washer using the punch on the side opposite to the one shown in the figure. Use the tool fitted with part 1 as shown in the figure and move the tool handgrip until the pin and the
SUSP - 76
Suspensions
NADELLA are simultaneously ejected in the direction opposite the tool thrusting force. After removing the pin and the first NADELLA, the swinging hub gets detached from the steering tube. To remove the second NADELLA, use the tool fitted with part 2 instead of part 1, on the side opposite the one shown in the figure.
N.B. DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE, THE ROLLER BUSHINGS ARE DESTROYED WHEN THE EXTRACTOR IS USED. UPON REFITTING, IT IS THEREFORE NECESSARY TO USE NEW BUSHINGS AS WELL AS A NEW PIN, NEW SEALING RINGS AND DUST GUARDS.
Specific tooling
020021Y Front suspension service tool Connect the swinging hub to the steering tube with the guiding pin. - Use the tool fitted with part 3 on the stem and part 4. Lubricate the pin with recommended grease and insert it temporarily on the swinging hub, move the tool handgrip until part 3 is fully inserted on the steering tube. After fitting the pin, insert the two spacers, slightly hitting them with the mallet.
N.B. BEFORE PROCEEDING WITH THE DESCRIBED FITTING, PLACE THE TWO DUST GUARD RINGS ON THE SWINGING HUB AS SHOWN IN THE FIGURE.
Specific tooling
020021Y Front suspension service tool
Recommended products
AGIP GREASE SM 2 Grease for odometer transmission gear case Lithium grease with NLGI 2 molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20
SUSP - 77
Suspensions
Insert the sealing ring on the pin and the roller bushing with its wedging washer at the same time. - Remove the tool and the part 5 (guide), which has been partially ejected during the previous pin fitting phase, and leave part 4 always fitted. - Replace part 3 with part 16 (on the stem). - By moving the tool handgrip, push the wedging washer - roller bushing - seal ring unit, placing part 16 until it stops on the swinging hub. - Repeat the above operation using the tool with part 16 and part 22, instead of part 4, always fitted to the stem, on the side opposite that indicated in the figure to fit the second wedging washer - roller bushing - sealing ring unit.
WARNING BEFORE PROCEEDING WITH THE DESCRIBED PRE-FITTING, DIP THE SEALING RINGS IN MINERAL OIL AND THE "NADELLA" ROLLER BUSHINGS (PREVIOUSLY WASHED IN PURE PETROL OR NEUTRAL PETROLEUM TO ELIMINATE THE ANTIRUST PROTECTION), HALF-FILLED WITH GREASE.
Specific tooling
020021Y Front suspension service tool
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20 - Use the tool fitted with part 20 on its stem and part 21 on the tool base as shown in the figure. - By moving the tool handgrip, push the two NADELLA bushings until their internal bottoms make contact with the pin end. - Use the tool fitted with parts 3 and 4 to fit the pin, and press moving the tool handgrip, until wedging the washers on the swinging hub. - Now, remove the two spacers (parts 17 and 16) and, once the space between the NADELLAs steering tube and swinging hub - has been fully
SUSP - 78
Suspensions
filled with grease, move the dust guard rings until they are placed in that space. - By wedging the washers as described above, the front suspension unit refitting stage is finished.
Recommended products
AGIP GREASE MU3 Grease for odometer transmission gear case Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
Refitting
Grease bearings and housings. Tighten to the prescribed torque and rotate the spanner in an anti-clockwise direction by 80-90.
Specific tooling
020055Y Wrench for steering tube ring nut
Recommended products
AGIP GP 330 Grease (brake level, throttle twistgrip, gaer) Calcium complex soap grease NLGI 2; ISO-LXBCIB2
SUSP - 79
Suspensions
Removal
Remove the 2 fixings shown in the figure and the 2 fasteners on the shock-absorber support bracket located on the steering column. Free the shock-absorber from the support bracket removing the top fixing.
Overhaul
In the event of grease leaks through the wheel hub, the cause may be found in the sealing ring fitted onto the calliper bracket. After removing the wheel hub, extract the ring shown in the figure and replace it with a new one.
Rear
SUSP - 80
Suspensions
SUSP - 81
Suspensions
Centre-stand
Detach the return spring from the centre stand, remove the 4 fasteners shown in the figure.
SUSP - 82
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
Refitting
When refitting, tighten the nuts to the prescribed torque. Bleed the system.
N.B.
* Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE ASSEMBLY.
Refitting
When refitting, correctly position the disc, observing the direction of rotation (see figure) and apply medium thread-lock. BRAK SYS - 84
Braking system
N.B.
* Safety tightenings IN ORDER TO ENSURE THE CORRECT TIGHTENING TORQUE, LUBRICATE NUTS BEFORE ASSEMBLY.
Recommended products
Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock
Disc Inspection
Remove the wheel and check any possible disc's out-of-plane. The measured value must be less than 0.1 mm. If higher, replace the disc and repeat the check. If the problem is not solved check and, if necessary, replace the wheel hub.
Specific tooling
020335Y Magnetic support for dial gauge
Refitting
When refitting, operate in the opposite way, paying attention in positioning the spring with the arrow pointing upwards.
BRAK SYS - 85
Braking system
Fill Front
Once the bleeding valve is shut, top-up the circuit using fresh brake fluid. Loosen the bleed screw. Connect the special tool's tube to the bleed hole. To bleed the system, constantly refill the reservoir, while pumping out air with the Mityvac, until all air has been removed from the circuit, i.e. only fluid is pumped out of the system. Tighten the bleed screw.
N.B.
IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS: IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS.
CAUTION
- DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL.
N.B.
DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, I.E. IT ABSORBS HUMIDITY FROM THE AIR. IF THE HUMIDITY LEVEL IN THE FLUID EXCEEDS A GIVEN VALUE, THE BRAKING PERFORMANCES MAY SERIOUSLY DETERIORATE. IT IS THEREFORE RECOMMENDED THAT FRESH FLUID IS TAKEN FROM NEW CONTAINERS. IN NORMAL CLIMATIC CONDITIONS, THE FLUID SHOULD BE REPLACED EVERY TWO YEARS. IF THE BRAKES ARE HIGHLY STRESSED, INCREASE THE FREQUENCY WITH WHICH THE FLUID IS REPLACED.
CAUTION
WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT.
Recommended products
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid With the operation concluded, tighten the bleed screw to the prescribed torque.
Specific tooling
020329Y MityVac vacuum-operated pump
BRAK SYS - 86
Braking system
Refitting
For refitting, perform the operation in the reverse order. Tighten the pipe to the prescribed torque and bleed the circuit.
BRAK SYS - 87
Braking system
After removing the hub, proceed as follows: 1. Remove the shoe spring using the special pliers. 2. Remove the two retainers shown in the figure. 3. Remove the shoes using a lever. 4. Fit the new shoes with the aid of a mallet. 5. Attach the return spring using the special pliers.
Specific tooling
020325Y Brake-shoe spring calliper Refit the components following the removal procedures in the reverse order, tightening the wheel nut to the prescribed torque.
WARNING -ALWAYS USE NEW SPLIT PINS FOR REFITTING. WARNING - FOLD THE EDGES OF THE SPLIT PIN AS SHOWN IN ORDER TO AVOID BACKSLASH BETWEEN THE CAP AND THE WHEEL AXLE.
After this operation it is possible to remove the fore brake cable retainer, removing the splint pin and its pin. It is also possible to replace the stop switch by acting upon its fixing.
BRAK SYS - 88
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Seat
Remove the 3 fasteners shown in the figure.
Headlight assy.
After removing the handlebar cover, remove the 2 fasteners show in the figure and the headlight adjusting screw underneath the handlebar. Detach the wirings. To replace the bulbs simply release the springs holding back the socket and replace any blown bulb.
CHAS - 90
Chassis
CHAS - 91
Chassis
Replace the seat and glove-box cylinders. To replace these follow the operations described for the removal of the cylinder when the ignition keyswitch is in the LOCK position. If the locks have been left open however, extract the cylinder by pushing lip F shown in the figure after having carefully cleaned the housing. Then insert the new cylinder. Bear in mind that for the replacement of the cylinder on the seat lock, it is necessary to remove the lock assembly, acting upon the three screws.
Taillight assy.
Remove the 2 fixings shown in the figure and replace the blown bulbs. Replace, if necessary, the taillight lens. To replace the taillight assy., remove the lens, detach the wiring and remove the 2 fasteners from underneath the frame.
CHAS - 92
Chassis
Fuel tank
After removing the seat, detach the electrical connection of the fuel level sensor. Remove the 2 remaining fixings to free the fuel tank assembly. Lift both tanks thus detaching the hoses with the fuel tap shut to separate the fuel-oil tanks. Remove the tank filler cap and insert the special tool through the tube. Proceed by loosening the nut and the acting upon ring B until releasing the oil tank.
Specific tooling
020321y Carburettor float removing tool 002850y Oil tank spanner 002973y Fuel tap spanner Remove the tank filler cap and insert the spanner thus loosening nut D, hence extract the fuel tap.
CHAS - 93
Chassis
Front mudguard
Remove the 2 fixings from underneath the mudguard.
After removing the handlebar and the steering column assembly, remove the 3 fasteners shown in the figure.
Top-case Front
Remove the 2 fixings shown in the figure and the 2 top fasteners from inside the glove-box. Remove the glove-box assembly.
CHAS - 94
Chassis
Side Cowlings
Lift the seat and act upon either one of the two lever, according to which cowling must be removed (RHS or LHS).
CHAS - 95
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Aesthetic inspection
Paint Plastic joints Damages Dirt
Electrical system
Fill the battery with acid, and charge with appropriate charger. Ignition key-switch. Low-beam light, high-beam light, warning lights, side-light. Headlight adjustment. Taillight. Stop light (eventually front and rear lights). Turn signal lights and warning lights. Dashboard illumination. Horn. Starter button.
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.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD. - BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. PRE DE - 97
Pre-delivery
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND 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
Brake fluid. Gear-box. Oil tank.
Road test
Cold start. Speedometer check. Throttle check. Riding stability. Front and rear brake efficiency. Front and rear shock-absorbers. Unusual noises. Hot engine restart. Leakages (after trial run).
Functional inspection
Brake lever excursion. Throttle excursion and adjustment. Homogeneous steering turning.
Other Tyre pressure. All locks. Rear-view mirrors and accessory fitting. Tooling kit, owner manual, warranty certificate and customer service card.
CAUTION
PRE DE - 98
INDEX OF TOPICS
TIME
TIME
Time
Engine
ENGINE
1 2 3 Code 001001 003064 003057 Action Engine from the frame - removal and refitting Engine oil - replacement Engine retainer - Tighten nuts Duration
TIME - 100
Time
Crankshaft
TIME - 101
Time
TIME - 102
Time
Flywheel cover
FAN COVER
1 Code 001087 Action Flywheel cover - Replacement Duration
TIME - 103
Time
Oil pump
AUTOMATIC MIXER
1 2 Code 001018 001028 Action Mixer - Replacement Oil pump drive shaft - Replacement Duration
Starter motor
STARTER MOTOR
1 2 3 Code 001020 001039 001038 Action Starter motor - change Starter motor brushes - Replacement Starter motor - Overhaul Duration
TIME - 104
Time
Code 001017
Duration
KICK-START LEVER
1 2 3 Code 008008 001120 001084 Action Kick-starter gear spring - Replacement Crankcase bearings - Replacements Starter lever - Replacement Duration
TIME - 105
Time
Flywheel magneto
FLYWHEEL MAGNETO
1 2 3 4 5 Code 001067 001004 001058 001059 003052 Action Stator - Removal and refitting Stator - Overhaul Flywheel - Replacement Pick-up - Replacement Ignition timing Duration
TIME - 106
Time
Carburettor
CARBURETTOR
1 2 3 Code 001063 001008 003058 Action Carburettor - Replacement Carburatore - Revisione Carburettor - Adjustment Duration
TIME - 107
Time
Exhaust pipe
EXHAUST PIPE
1 Code 001009 Action Exhaust pipe - Replacement Duration
TIME - 108
Time
Air cleaner
AIR CLEANER
1 2 Code 001014 001027 Action Air filter - Replacement Air-cleaner/frame bellow - Replacement Duration
TIME - 109
Time
Frame
FRAME
1 2 3 Code 004001 006001 004023 Action Frame - Replacement Frame - Painting Shield rim - Replacement Duration
TIME - 110
Time
Centre-stand
CENTRE-STAND
1 Code 004004 Action Centre-stand - Replacement Duration
Legshield spoiler
TIME - 111
Time
Side fairings
TIME - 112
Time
Footrests
TIME - 113
Time
FOOTRESTS
1 Code 004015 Action Footrests - Replacement Duration
Rear cover
GLOVE-BOX
1 2 3 Code 004083 006019 004081 Action Glove box - Replacement Glove-box - Painting Glove-box door - Replacement Duration
TIME - 114
Time
Mudguard
FRONT MUDGUARD
1 2 3 Code 004002 006003 003045 Action Front mudguard - Replacement Mudguard - Painting Steering tube - Replacement Duration
TIME - 115
Time
Fuel tank
TIME - 116
Time
FUEL TANK
1 2 3 4 Code 004005 004007 004110 006024 Action Fuel tank - Replacement Fuel tap - Replacement Fuel tank hose - Replacement Fuel tank - Painting Duration
Tank oil
OIL TANK
1 Code 004017 Action Oil tank - Replacement Duration
TIME - 117
Time
Rear shock-absorber
REAR SHOCK-ABSORBER
1 Code 003007 Action Rear shock-absorber - Removal and refitting Duration
TIME - 118
Time
Handlebar components
TIME - 119
Time
2 3 4
Action Front brake pump - Removal and refitting Front brake fluid - Replacement and circuit bleeding Front brake hose - Removal and refitting
Duration
GEAR-SHIFTER TWIST-GRIP
1 2 3 4 Code 005062 002071 002037 001035 Action Neutral switch - Replacement Left hand grip - Replacement Brake or clutch lever - Replacement Clutch lever - Replacement Duration
TIME - 120
Time
Seat
SEAT
1 2 Code 004003 004054 Action Saddle - Replacement Saddle lock catch - Replacement Duration
TIME - 121
Time
Instrument panel
TIME - 122
Time
TAILLIGHT
1 2 3 Code 005066 005005 005028 Action Rear light bulbs - Replacement Taillight - change Rear light assembly glass - Replacement Duration
TIME - 123
Time
HEADLIGHT
1 2 Code 005008 005002 Action Headlight bulbs - Replacement Front light - Replacement Duration
TIME - 124
Time
Front wheel
WHEEL
1 2 3 4 5 Code 004123 003047 003037 006018 003063 Action Front wheel - Replacement Front tyre - replace Front wheel rim - Removal and Refitting Wheel rim - Paintwork Tyre pressure - Check Duration
Grease tone wheel or drive Please take note that the code has been introduced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide). In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 125
Time
Electric devices
ELECTRICAL DEVICES
1 2 Code 005024 005025 Action Battery fuse - Replacement Battery fuse holder - Replacement Duration
TIME - 126
Time
TIME - 127
Time
ELECTRICAL CONNECTIONS
1 Code 005001 Action Electric circuit - Replacement and Refitting Duration
ELECTRICAL DEVICES
1 2 Code 005013 005045 Action Electronic blinker - Replacement Starter motor wire harness - Replacement Duration
TIME - 128
Time
ELECTRICAL DEVICES
1 2 3 Code 005003 005017 005069 Action Horn - Replacement Stop light switch - Replacement Left switch - Replacement Duration
TIME - 129
Time
ECU - CDI
1 Code 001023 Action CPU - Replacement Duration
Transmissions
CABLES
1 2 3 4 5 Code 002008 002056 002051 002049 002046 Action Choke cable - Replacement Gear shifter cable assy. - Replacement Odo/Speedometer cable assy. - Replacement Odometer cable - Replacement Gear shifter cable - Replacement Duration
TIME - 130
Time
CABLES
1 2 3 4 5 6 Code 002055 002063 002053 003060 003061 002045 Action Clutch cable assy. - Replacement Throttle cable assy. - Replacement Rear brake transmission complete replacement Rear brake cable - Adjustment Accelerator transmission - Adjustment Clutch cable - Replacement Duration
TIME - 131
Time
Brake callipers
BRAKE CALLIPERS
1 2 3 Code 003070 002007 002039 Action Front brake pads - Wear check Front brake pads - Removal and refitting Front brake calliper - Removal and refitting Duration
TIME - 132
Time
Steering column
STEERING COLUMN
1 Code 003010 Action Front suspension - Service Duration
TIME - 133
Time
Front suspension
FRONT SHOCK-ABSORBER
1 Code 003011 Action Front shock absorber - Removal and Refitting Duration
TIME - 134
Time
Braking system
TIME - 135
Time
TIME - 136
Time
SHOE PLATE
1 Code 002016 Action Rear brake shoe plate - Replacement Duration
TIME - 137
Time
Code 003012
Duration
TIME - 138
Time
Clutch cover
CLUTCH COVER
1 Code 001073 Action Clutch cover - Removal and refitting Duration
Clutch
CLUTCH
1 Code 001022 Action Clutch - Removal Duration
TIME - 139
Time
Gear-box
GEAR-BOX
1 2 Code 001119 001025 Action Gearbox components - Replacement Gearbox - Overhaul Duration
Gear shifter
GEAR SHIFTER
1 Code 001029 Action Gear shifter Overhaul Duration
TIME - 140
Time
TIME - 141
A
Air filter: 31
B
Battery: 40, 48 Brake: 84, 85, 87, 88, 132 Brake fluid:
C
Carburettor: 10, 30, 63, 64, 66, 107
F
Fuel: 64, 93, 116 Fuses: 47
H
Headlight: 32, 90 Horn:
I
Identification: 7 Instrument panel: 122
M
Maintenance: 7, 26
S
Shock absorbers: 81 Spark plug: 31
T
Tank: 93, 116, 117 Transmission: 9 Tyres: 10