Derbi GP1 125-250 c.c., GP1 125 c.c., GP1 250 c.c. Workshop Manual

WORKSHOP MANUAL

GP1 125-250 c.c.

DERBI - NACIONAL MOTOR, S.A.U., manufacturer of DERBI motorcycles and mopeds, has produced this
manual with the aim of documenting and simplifying as much as possible the work you need to do to in dis­mantling and assembling the GP1 125/250 c.c.

The intention is to provide as much assistance as possible to mechanics working for our brand’s dealers and
sub-dealers.

Due to its constant commitment to improving its products, DERBI - NACIONAL MOTOR, S.A.U. Sociedad
Unipersonal reserves the right to introduce any modifications it deems fit, without prior warning.

All the information included in this manual is based on the latest data available at the time of its publication.
The drawings and photographs in this manual are for reference purposes only, and may therefore not be
exactly the same as the corresponding parts of the current model itself.

NACIONAL MOTOR, S.A.U.

1

INTRODUCTION

GENERAL INFORMATION

GENERAL TECHNICAL DATA

RECOMMENDED TOOLS

PERIODIC MAINTENANCE

DISMANTLING

SEAT SIDE TRIM

COWLING

COWLING BOTTOM COVER

WATER-OIL TANK COVER

SIDE COVERS

SHIELD INNER COVER

BATTERY COVER

PETROL TANK COVER

HELMET CARRIER

FOOTRESTS

SIDE COVERS

SHIELD

ENGINE

EXHAUST ASSY - REMOVAL

REMOVAL OF THE WNGINE FROM THE VEHICLE

AUTOMATIC TRANSMISSION

AIR DUCT

REMOVING THE DRIVEN PULLEY SHOFT BEARING

REFFITING THE DRIVEN PULLEY SHOFT BEARING

BAFFLE ROLLER

REMOVING THE DRIVEN PULLEY

INSTEPTING THE CLUTCH DRUM

REMOVING THE CLUTCH

INSPECTING THE CLUTCH

PIN RETAINING COLLAR

REMOVING THE DRIVEN HALF-PULLEY BEARING

INSPECTING THE DRIVEN FIRED HALF-PULLEY

INSPECTING THE DRIVEN SUDING HALF-PULLEY

REFITTING THE DRIVEN HALF-PULLEY BEARING

REFITTING THE DRIVEN PULLEY

INSPECTING THE CLUTCH SPRING

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3

REFITTING THE CLUTCH

REFITTING THE DRIVEN PULLEY

DRIVE-VELT

REMOVING THE DRIVING PULLEY

INSPECTING THE ROLLERS CASE

REFTTING THE DRIVING PULLEY

REFITTING THE TRANSMISSION COVER

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END GEAR

REMOVING THE WHEEL AXLE

REMOVING THE HUB BEARING

REMOVING THE WHEEL ASXLE BEARING

REMOVING THE DRIVEN PULLEY SHAFT BEARING

INSPECTING THE HUB SHAFT

INSPECTING THE HUB COVER

REFITTING THE WHEEL AXLE BEARING

REFITTING THE HUB COVER BEARING

REFITTING THE HUB BEARING

REFITTING THE HUB COVER

FLYWHEEL COVER

REMOVING THE STATOR

FLYWHEEL AND STARTING

REMOVING FLYWHEEL MAGNETO

INSPECTING THE FLYWHEEL COMPONENTS

REFITTING THE FLYWHEEL MAGNETO

REFITTING THE STATOR MOTOR

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CYLINDER ASSY AND TIMING SYSTEM

REMOVING THE ROCKER ARMS COVER

REMOVING THE CAMSHAFT

REMOVING THE CYLINDER HEAD

REMOVING THE VALVES

REMOVING THE CYLINDER - PISTON ASSY

INSPECTING THE SMALL END

INSPECTING THE WRIST PIN

INSPECTING THE PISTON

INSPECTING THE CYLINDER

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4

INSPECTING THE PISTON RING

REMOVING THE PISTON RING

CHOOSING THE GASKET

COMPRESSION RATIO VERSION 250

REFITTING THE PISTON RINGS

REFITTING THE CYLINDER

INSPECTING THE CYLINDER HEAD

INSPECTING THE TIMING SYSTEM COMPONENTS

INSPECTING THE VALVE SEALINGS

INSPECTING THE VALVE HOUSINGS

INSPECTING THE VALVES

INSPECTING THE SPRINGS AND HALF-CONES

REFITTING THE VALVES

INSPECTING THE CAMSHAFT

REFITTING THE TIMING SYSTEM COMPONENTS

REFITTING THE ROCKER - ARMS COVER

REFITTING THE INTAKE MANIFOLD

REFITTING THE TIMING SYSTEM COMPONENTS

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CRANKCASE - CRANKSHAFT

INSPECTING THE CRANSHFT ALIGNMENT

INSPECTING THE CRANKCASE HALVES

INSPECTING THE CRANKSHAFT PLAIN BEARING

REFITTING THE CRANKCASE HALVES

LUBRICATION

OIL PRESSURE CHACK

OIL PUMP

INSPECTION

REFITTING

REMOVING THE OIL - SUMP

INSPECTING THE BY-PASS VALVE

REFITTING THE OIL SUMP

SAS VALVE

INSPECTING THE CUT-OFF

FUEL SUPPLY

REFITTING THE CARBURETTOR

LEVEL CHECK

INSPECTING THE VALVE AND NEEDLE

INSPECTING THE AUTOMATIC CHOCKE DEVICE

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5

FORK, SHOCK ABSORBER. ENGINE SUPPORT AND STAND

DISMANTLING FRONT SUSPENSION

INSPECTING THE FRONT FORKS

DISMANTLING

INSPECTION
SWING-ARM

CHECKING THE SWINING ARM

EXHAUST BRACKET

OVERHAUL

REFITTING

CENTRE - STAND

FRONT WHEEL AND BRAKES

REAR WHEEL 125 C.C.
REAR WHEEL 250 C.C.

DISMANTLING

INSPECTING THE FRONT WHEEL

DISMANTLING THE FRONT DISCK CALLIPER

ASSEMBLING THE FRONT WHEEL

REAR WHEEL AND BRAKES

REAR WHEEL 125 C.C.
REAR WHEEL 250 C.C.

DISMANTLING

DISMANTLING THE REAR DISCK CALLIPER

INSPECTING THE REAR WHEEL

RIFTTING THE REAR WHEEL

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CIRCUITO DE REFRIGERACIÓN

CIRCUIT DIAGRAM 250 C.C.
CIRCUIT DIAGRAM 150 C.C.

WATER PUMP - OVERHAUL

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM GP1 125-250 C.C.

CHECK CONNECTORS

INSPECTIONS STEPS

DIGITAL INSTRUMENTS UNIT

IGNITION

LIGHTS AND AUTOMATIC CHOKE

RECHARGING THE BATTERY AND STARTTING

6

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SENSORS AND INDICATORS

TURN INDICATORS AND HORN

IGNITION CIRCUIT

SPARK PLUG

STATOR CHECK

VOLTAGE REGULATOR CHECK

FUSES

DISMANTLING THE BATTERY

BATTERY - INITIAL CHARGE

CAPACITY

INSPECTION THE CHARGING CONDITIONS

RECHARGING

CHARGING SYSTEM

TROUBLESHOOTING

ENGINE

REAR WHEEL TURNS WITH ENGINE TICKING OVER

DIFFICULTY STARTING

EXCESSIVE CONSUMPTION OF OIL/SMOKY EXHAUST

INSUFFICIENT LUBRICATION PRESSURE

THE ENGINE TENDS TO STOP AT MAX GAS OPENING

THE ENGINE TENDS TO STOP AT IDLE

HIGH CONSUMPTION

EXCESSIVELY NOISY WITH EXHAUST

SECONDARY AIR DEVICE ANOMALIES

TRANSMISSION AND BRAKES

INSUFFICIENT BRAKING

BRAKES OVERHEATING

VARIATIONS OR REFRAINED NOISINESS

BATTERY

FLASHING LICHTS NOT WORKING

HEARDENING STERRING

EXCESSIVE STEERING PLAY

NOIZY SUSPENSION

SUSPENSION OIL LEAKAGE

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7

REGULATIONS

GU O S

S GUOS

MAINTENANCE REGULATIONS

This section describes the machine’s general safety and maintenance work rules.

SAFETY REGULATIONS

- In the event of having to carry out work on the engine while this is running, ensure that the area is well
ventilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases
are poisonous.

Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the
work area, nor should there be naked flames or sparks.

MAINTENANCE REGULATIONS

- Use genuine DERBI spare parts and lubricants recommended by the manufacturer. Non-genuine or unau­thorised parts may damage the engine.

Always use new gaskets and oil seals during re-assembly.

After dismantling, clean the components with solvents that are non-inflammable or with a high flammability
point. Lubricate all working surfaces before assembling, excluding tapered joints.

After assembly, check that all components have been correctly fitted and that they are functioning perfectly.

For dismantling, checking and assembly operations, use only tools with metric measurements. Metric screws,
nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable tools
and joining devices may damage the engine.

- In the case of work on the engine involving the electrical circuitry, check that electrical connections have
been correctly fitted.

N.B.

Indicates a note that gives key information to make the procedure easier and clearer.

ATTENTION

Indicates specific procedures that must be carried out to avoid damage to the machine.

WARNING

Indicates specific procedures that must be followed to avoid possible accidents to the person repairing the
machine.

8

G

5

c.c.

G

50

c.c.

MACHINE ENGINE PREFIX FRAME PREFIX

P1 12

GP1 125 c.c.

P1 2

GP1 250 c.c.

M434M

M237M

DIMENSIONS AND WEIGHT

VTHPS1A1A

VTHPT1A1A

SPECIFICATIONS

Maximum length
Maximum height
Length between axles
Handlebar width
Handlebar height

ENGINE

SPECIFICATIONS

Engine type

Timing

Int. diameter per stroke (125)
Int. diameter per stroke (250)
Cubic capacity (125)
Cubic capacity (250)
Compression ratio (125)

DESC. / QUANTITY

1930 mm.
1225 mm.
1375 mm.
705 mm.
1085 mm.

DESC. / QUANTITY

Single cylinder four-stroke and four valve water-cooled

Single overhead cam driven by a chain on the left-hand
side; rockers with three arms and with threaded adjus­ter.

57x 48,6mm
72 x 60 mm
124,015 cm
244,290 cm

3

3

12:1

9

ENGINE

SPECIFICATIONS

Compresion ratio (250)
Keihin Carburettor (125 - 250)
Walbro Carburettor (125)
Walbro Carburettor (250)
Idle speed
Adjustment CO
Air filter

Starter system
Lubrication

Feeding

Max. power (crankshaft) 125cc
Max. power (crankshaft) 250cc

TRANSMISSION

DESC. / QUANTITY

10,5-11,5: 1
CVEK-30
WVF 7G* 0 29
WVF-7S*
1650 ±50 r.p.m.
3,8 ± 07
Sponge-type damped eith a 50% for filters.

Oil - 50% unleaded petrol misture
Electric starter motor

Engine lubrication with geared twin-screw pump (inside the
oil sump) coomanded by chain and double paper net filter.

With depression pump and petrol through carburettor

11 kw (15CV)at 9700p.r.m.
16,18 Kw (22CV) at 8250 p.r.m.

Transmission

CAPACITIES

Engine oil (125)
Engine oil (250)
Fuel tank
Rear hub oil

SPECIFICATIONS

SPECIFICATIONS

DESC. / QUANTITY

Automatic expandable pulley varistor with servosystem,
trapezoidal belt, self-ventilating dry automatic centrifu­gal clutch, gear reducer and transmission compartment
with forced air circulation.

DESC. / QUANTITY

~ 1100 cc
~ 1200 cc
~ 11 L. with reservation of 2,7 L.)
250 cc

10

ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS

SPECIFICATIONS

Ignition type

Ignition advance (before T.D.C) 125

(

Ignition advance

Spark plug (125)
Spark plug (250)
Battery
Fuses
Generator

before T.D.C

FRAME AND SUSPENSIONS

SPECIFICATIONS

Type

Front suspension

Front wheel max. travel
Rear suspension

DESC. / QUANTITY

Electronic with capacitive discharge (CDI) and variable
advance with separate HT coil.

10°±1° at 2000 r.p.m. - 34°±1° at 6000 r.p.m.

)

10° ± 1 at 2000g/min.
28° ± 1 at 6500 g/min.

CHAMPION RG4HC
CHAMPION RG4HC
12V-12Ah
N°1 15A / N°2 15A / N°3 15A
AC current

DESC. / QUANTITY

Aluminium alloy Delta Box type

Hydraulic telescopic fotk with forward-shifted pin and
Ø 40 mm rods.

100 mm

Engine functioning as swingarm pivoting on frame
through arm with two degrees of freedom. Pair of
double-acting hydraulic shock absorbers and coaxial
springs with preload adjustment.

Max. rear shock absorber travel

BRAKES

SPECIFICATIONS

Brakes front

Brakes rear

11

90/85 mm

DESC. / QUANTITY

Ø 245 mm disc with hydraulically operated dual piston
floating caliper (lever at right end of handlebar).

Ø 240 disc with hydraulically operated dual opposed
piston caliper (lever at left end of handlebar).

WHEELS AND TYRES

SECONDARY AIR

SPECIFICATIONS

Front wheel rim
Rear wheel rim
Front tyre
Rear tyre
Tyre pressure front wheel (cold)
Tyre pressure rear wheel (cold)
Tyre pressure rear/front wheel (driver and
passenger). (cold)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AM­BIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO
THE WEIGHT OF THE RIDER AND ACCESSORIES.

Aluminium alloy
In light alloy
120 / 70 x 14”
120 / 60 x 14”
1,9 bar
2,0 bar
2,0 / 2.2 bar

SECONDARY AIR

DESC. / QUANTITY

The working principie of the SAS for Leader 125 ce engines is
entirely similar to the SAS employed on 2-stroke engines.

The main differences are the following:

Secondary air enters directly into the exhaust duct on the
cylinder head, instead of entering through the exhaust pipe
as in two-stroke engines.

The reed valve found on 2-stroke engines is here replaced by
a membrane. The unit, indicated by an arrow in the figure, is
provided with a cut-off connected to the vacuum inlet on the
intake manifold to shut air intake during deceleraron, so to
prevent detonations in the silencer.

Air is sucked in through hole «A» and flowing through the
first filter is directed towards hole «B».

12

Flowing through the hole shown in the figure, the air reaches
the second filter, «B», At this point, the tiltered air enters the
membrane device, so to be channelled towards the head.

Flowing through a rigid pipe, flanged to the head, the se­condary air reaches the exhaust duct thus providing oxygen
addition to the unburnt gases just before they enter the ca­taiytic converter. The efficiency ofthe catalyzing process is
therefore increased.

El sistema de funcionamiento del SAS para motor Quasar
250 Euro 2 es totalmente similar al funcionamiento del siste­ma SAS para motor 2T.

Las diferencias son las siguientes:

El aire secundario, en vez de entrar en el silenciador, como
sucede para el 2T entra directamente en el conducto de des­carga sobre la culata.

13

The working principie ofthe SAS for Quasar 250 cc Euro 2
engines is entirely similar to the SAS employed on 2-stroke
engines. The main differences are the following:

Secondary air enters directly into the exhaust duct on the
cylinder head, instead of entering through the exhaust pipe
as in two-stroke engines.

The reed valve found on 2-stroke engines is here replaced
by a membrane.

Unit «A», shown in the figure, is provided with a cut-off con­nected to the vacuum inlet on the intake manifold to shut air
inlet during deceleration, so to prevent detonations in the
silencer. Air is sucked in through hole «B» and flows inside
the duct into air-box «C» where it is filtered by filtering ele­ment «D».

The filtered air now enters membrane device «A», through
duct «E» and is then guided towards the head.

Flowing through pipe «F», flanged to the head, secondary
air reaches the exhaust duct thus providing oxygen addition
to the unburnt gases just before they enter the catalytic con
verter.

The efficiency of the catalyzing process is therefore increa­sed.

14

CARBURATTOR HEIHIN

Version 125

SPECIFICATION

Depresione type
Printing on the body
Device CUT-OFF
Max. jet
Minimum jet
Max. air jet
Minimum air jet
Idle mixture adjusment screw initial opening
Conical pin
Emulsifier nozzle
Starter air jet
Starter jet
Starter device resistance
Venturi choke
Throttle valve
Choke maximum cone

CARBURETTOR WALBRO

DESC. / QUANTITY

CVEK30
CVK
Not present
105
35
70
130
2 ±1/4
Ø 2,450
Ø 2,8
Ø 1,5
42
~20 
Ø 29
Ø 30,5
Ø 47

SPECIFICATION

Type to depression
Printing on the body
Device CUT-OFF
Max jet
Minimum jet
Max air jet.
Minimum air jet
Gas valve spring
Idle mixture adjustment screw initial opening
Conical pin printing
Conical pin notches position from top
Emulsifier nozzle
Choke máximum cone
Starter air jet
Starter emulsifier jet

15

DESC. / QUANTITY

WVF-7G*
7G

Not present
108
36
115
100
100 gr
2 5/8 ± 1/2
51C
2
Ø 2,7
Ø 1,5
200
130

CARBURADOR WALBRO

SPECIFICATION

Starter jet
Starter pin diameter
Starter device resistance
Choke
Throttie valve
Choke máximum cone

CARBURATTOR HEIHIN

Version 250

SPECIFICATION

Depression type
Printing on the body
CUT-OFF device
Max jet
Minimum jet
Max air jet
Mínimum air jet
Idle mixture adjustment screw initial opening
Conical pin
Emulsifier nozzle
Starter air jet
Starter jet
Starter device resistance
Venturi choke
Throttie valve
Choke máximum cone

DESC. / QUANTITY

50

Ø 1,78

~ 40Q

Ø 29 (30,3x27,0)

Ø 33

Ø 48,0

DESC. / QUANTITY

CVEK30

CVK

Present

100

38

70

115

2½ ± ¼

Ø 2,530

Ø 2,8

Ø 1,5

42

~ 20 

Ø 29

Ø 30,5

Ø 47

16

CARBURATTOR WALBRO

Version 250

SPECIFICATION

Depression type
Printing on the body
CUT-OFF device
Max jet
Minimum jet
Max air jet
Mínimum air jet
Gas valve spring
Idle mixture adjustment screw initial opening
Conical pin
Tacche dall’alto spillo cónico
Emulsitier nozzle
Choke máximum cone
Starter air jet
Starter emulsifier jet
Starter jet
Starter pin diameter
Starter device resistance
Choke
Throttie valve
Choke máximum cone

* The identification letter can vary every time the carburettor is updated.

WVF-7S*

7S

Presente

118

34

150

31

120 gr

3±½

465

3

Ø 2,7

Ø 1,5

200

130

50

Ø 1,78

~ 40

Ø 29 (30,3x27,0)

Ø 33

Ø 48,0

DESC. / QUANTITY

17

CHASSIS TIGHTENING TORQUES

DESCRIPTION

M8X125 8.8 FRONT FRAME-CHASSIS SECUR.DEVICE
M8X125 8.8 SUBCHASSIS-CHASSIS SEC.DEVICE
M10x150 12.9 TOP SHOCK ABSOR.-CHASSIS SEC.DEVICE
M10x150 12.9 BOTTOM SHOCK ABSOR.-ENG. SEC.DEV.
M14x200 8.8 FRONT ENG. SUPPORT-CHASSIS SEC.DEV.
M10X150 8.8 REAR ENG.SUPP-FRONT ENG.SUPP. SEC.DEV.
M10X150 8.8 ENGINE-REAR SUPP. SEC.DEV.
M8X125 8.8 ENGINE SUPP. SILENTBLOC CLAMP SEC.DEV.
M8X125 8.8 SHOCK ABSORBER SUPP. SEC.DEV.
M8X125 12.9 SHOCK ABSOR. SUPP. TO CRANKCASE SEC.DEV.
M12X175 12.9 SHOCK ABSORBER SUPP. TO SUSP. ARM SEC.DEV. M12X175 12.9
M30,5X150 FORKS FLANGE SEC.DEV.
M6x100 HORN-CHASSIS SEC.DEV.
M10X150 8.8 STAND SEC.DEV.
M8Z125 8.8 FOOTREST SUPPORT-CHASSIS SEC.DEV.
M7x100 8.8 EXHAUST PIPE-CYLINDER SEC.DEV.
M8X125 8.8 SILENCER-SUSPENSION ARM SEC.DEV.
M6x100 8.8 STEERING LOCK-CHASSIS SEC.DEV.
M8x125 8.8 HANNDLEBARS-STEERING FORKS SEC. DEV.
M8x125 8.8 HANDLEBAR CLAMP SEC.DEV.
M5x80 8.8 COUNTERWEIGHT-HANDLEBAR SEC.DEV.
M14x150 FRONT WHEEL-FORKS SEC.DEV.
M8x125 FORK ARM LOCK SEC.DEV.
M6x100 10.9 BRAKE DISK-FRONT WHEEL SEC.DEV.
M10x150 8.8 FR. BRAKE CALLIPER-FORKS SEC.DEV.
M8X125 12.9 SUSP. ARM-ENGINE SEC. DEV.
M16X125 10.9 REAR HUB-ENGINE SEC.DEV.
M8X40 10.9 REAR WHEEL-HUB SEC.DEV.
M8X125 8.8 REAR CALLIPER SUPP.-CRANKCASE SEC.DEV.
M8X125 8.8 REAR CALLIPER-CALLIPER SUPP. SEC.DEV.
M6x100 10.9 BRAKE DISK-REAR HUB SEC. DEV.
M8x125 8.8 CLAMP-CHASSIS SEC.DEV.
M6x100 RADIATOR-CHASSIS SEC.DEV.
THERMOSTAT SWITCH-RADIADOR SEC.DEV.
M5X80 8.8 ELECT.FAN-CHASSIS SEC.DEV.
M5x80 VARIOUS METAL PARTS TO CHASSIS SEC.DEV
M6x100 VARIOUS METAL PARTS TO CHASSIS SEC.DEV.
M8x125 VARIOUS METAL PARTS TO CHASSIS SEC.DEV.
M5x80 VARIOUS PLASTIC PARTS TO CHASSIS SEC.DEV.
M6x100 VARIOUS PLASTIC PARTS TO CHASSIS SEC.DEV.

(•) Sellador the thread type locktite 243

TORQUES

(N.M)

1,7÷1,9

1,7÷1,9
4,5÷5,5
4,5÷5,5

7÷8
3÷4

3÷4
1,7÷1,9
1,7÷1,9

3÷3,5
6÷6,5

9÷13

0,8÷1

3÷4
1,7÷1,9

1÷1,3

1,7÷1,9

0,8÷1
1,7÷1,9
1,7÷1,9

0,35÷0,45

7÷8

1,5÷1,9

1÷1,2

3,5÷4

2,2÷2,5

11, 5÷12,5

2,7÷2,9
1,7÷1,9
1,7÷1,9

1÷1,2

1,7÷-1,9

0,8÷1

1,7÷2,2

0,4÷0,5

0,35÷0,45

0,8÷1

1,5÷1,9

0,1÷0,2

0,2÷0,35

TORQUES

(M.KG)

17÷19

17÷19
45÷55
45÷55
70÷80
30÷40
30÷40

17÷-19

17÷19

30÷35
60÷65

90÷130

8 ÷ 10

30÷40

17÷19
10÷13

17÷19

8÷10
17÷19
17÷19

3,5÷4,5

70÷80

15÷19

10÷12
35÷40
22÷25

115 ÷12 5

27÷29

17÷19
17÷19

10÷12

17÷19

8÷10
17÷22

4÷5

3,5÷4,5

8÷10
15÷19

1÷2

2÷3,5

SEALER

.

.
.
.

.
.
.

18

EXAUST PIPE

NAME

Screw clamping manifold to silencer
Screw clamping heat shield to silencer
Exhaust gas intake screw
Screw fixing silencer support arm to crankcase
Exhaust pipe/support bracket fixing screw.
Exhaust pipe/cylinder head fixing nut.

ENGINE - LUBRICATION

NAME

Hub oilexhaust cap
Oil filter unión on crankcase
Engine oil / net filter drainage cap
Oil filter
Oil pump cover screws
Screws fixing the oil pump to the crankcase
Oil pump control rim screw
Oil pump cover píate screws
Oil sump screws
Minimum oil pressure sensor

TORQUE IN Nm

15,5 ÷ 18,5
5 ÷ 6
22 ÷ 26
33 ÷ 41
27 ÷ 30
16 ÷ 18

TORQUE IN Nm

15 ÷ 17
27 ÷ 33
24 ÷ 30
4 ÷ 6
0,7 ÷ 0,9
5 ÷ 6
10 ÷ 14
4 ÷ 6
10 ÷ 14
12 ÷ 14

CYLINDER HEAD

NAME

Spark plug
Cylinder head cover screw (1) (A)
Head fastening side screws
Start up mass screws

M5 side screw fastening washers on cam
shaft (125 cc)

19

TORQUE IN Nm

12 ÷ 14
9 ÷ 11 + 180°
11 ÷ 13
7 ÷ 8,5
7 ÷ 8,5

CYLINDER HEAD

NAME

Tappet adjustment lock nut
Timing chain tightener sliding block screws
Start up mass bell screws
M6 central screw fastening washers on
cam shaft (125 cc)
Timing beit tightener support screw
Timing beit tightener central screw
Camshaft retain píate screw

TRANSMISSION

NAME

Beit support roller screw
Clutch assembly nut on driven pulley
Driving pulley screw
Transmission cover screw
Driven pulley axis
Hub cover screws

TORQUE IN Nm

6 ÷ 8
10 ÷ 14
11 ÷ 15
11 ÷ 15

11 ÷ 13
5 ÷ 6
4 ÷ 6

TORQUE IN Nm

11 ÷ 13
45 ÷ 50
75 ÷ 83
11 ÷ 13 Nm
54 ÷ 60
24 ÷ 27

FLYWHEEL

NAME

FIywheel cover fastening
Stator cover screws (°)
FIywheel nut (125)
FIywheel nut (250)
Pick-Up fixing screws
Free wheel fixing screws on the flywheel

20

TORQUE IN Nm

5 ÷ 6
3 ÷ 4
52 ÷ 58
94 ÷ 102
3 ÷ 4
13 ÷ 15

ENGINE CRANKCASE AND SHAFT

NAME

Engine crankcase inside head screws
(transmission side half shaft)

Engine crankcase coupling screws
Starter motor screws
Crankcase timing cover screws

4 ÷ 6

11 ÷ 13
11 ÷ 13
3,5 ÷ 4,5

TORQUE IN Nm

COOLING

NAME

Water pump impeller cover
Water pump impeller drive joint screw
Thermostat cover screws

(°) Apply threadlocking LOCTITE médium, type 242.

(*) Tighten the two screws after tightening the rear wheel spindie nut with the prescribed torque.

(A)Tighten the nuts ¡n two phases, following a crosswise pattern.

3 ÷ 4
3 ÷ 4
3 ÷ 4

TORQUE IN Nm

(1) Lubrícate nuts with engine oil before fitting.

21

OVERHAUL DATA

ASSEMBLY CLEARANCES
CYLINDER - PISTON ASSY

CATEGORIES COUPLING 125

NAME

Cylinder
Cylinder
Piston
Piston
Cylinder first uprat.
Cylinder first uprat.
Piston first uprat.
Piston first uprat.
Cylinder second uprat.
Cylinder second uprat.
Piston second uprat.
Piston second uprat.
Cylinder third uprat.
Cylinder third uprat.
Piston third uprat.
Piston third uprat.

PLAY

57+0,025±0,003
57+0,025±0,003

56,959±0,014

56,959±0,014
57,2+0,025±0,003
57,2+0,025±0,003

57,159±0,014

57,159±0,014
57,4+0,025±0,003
57,4+0,025±0,003

57,359±0,014

57,359±0,014
57,6+0,025±0,003
57,6+0,025±0,003

57,559±0,014

57,559±0,014

INITIALS

A
B
C

D
A1
B1

C1
D1
A2

B2

C2
D2
A2

B3

3C
D3

CYLINDER

56,997 ÷ 57,004

57,004 ÷ 57,011
57,011 ÷ 57,018
57,018 ÷ 57,025
57,197 ÷ 57,204
57,204 ÷ 57,211
57,211 ÷ 57,218
57,218 ÷ 57,225

57,397 ÷ 57,404

57,404 ÷ 57,411
57,411 ÷ 57,418
57,418 ÷ 57,425

57,597 ÷ 57,604

57,604 ÷ 57,611

57,611 ÷ 57,618

57,618 ÷ 57,625

PISTON

56,945 ÷ 56,952
56,952 ÷ 56,959
56,959 ÷ 56,966
56,966 ÷ 56,973

57,145 ÷ 57,152
57,152 ÷ 57,159
57,159 ÷ 57,166

57,166 ÷ 57,173
57,345 ÷ 57,352
57,352 ÷ 57,359

57,411 ÷ 57,418
57,366 ÷ 57,373
57,545 ÷ 57,552
57,552 ÷ 57,559
57,559 ÷ 57,566
57,566 ÷ 57,573

PLAY ON

FITTING

0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059
0,045-0,059

22

on

n

r

ylinder

COUPLING CATEGORIES ENGINE 250

NAME

Cylinder

C
Cylinde

Cylinder
Pisto

Piston
Pist

Piston

PISTON RINGS

PLAY

72+0,018±0,010
72+0,018±0,010

71,967±0,014
71,967±0,014

INITIAL

A

B
C
D

CYLINDER

71,990 ÷ 71,997
71,997 ÷ 72,004
72,004 ÷ 72,011

72,011 ÷ 72,018

PISTON

71,953 ÷ 71,960
71,960 ÷ 71,967
71,967 ÷ 71,974
71,974 ÷ 71,981

PLAY ON FITTING

0,030-0,044
0,030-0,044
0,030-0,044
0,030-0,044

UPRATING TABLE ENGINE 125

NAME

Compression lining
Scraper ring lining
Scraper ring lining

DESCRIPTION DIMENSIONS

57 x 1

57 x 1

57 x 2,5

INITIALS

A

A

A

QUANTITY

0,15 ÷ 0,30

0,10 ÷ 0,30

0,15 ÷ 0,35

23

OVERSIZES ENGINE 250

NAME

Compression lining
Scraper ring lining
Scraper ring lining

DESCRIPTION DIMENSIONS

72 x 1,5

72 x 1

72 x 2,5

CRANKCASE - CRANKSHAFT - CONNECTING ROD

CRANKCASE - DRVING SHAFT - BENCH HALF BEARING

NAME

Half crankshaft bearing
Half crankshaft bearing
Half crankshaft bearing
Crankshaft cat. 1 - Crankcase cat. 1
Crankshaft cat. 1 - Crankcase cat. 2
Crankshaft cat. 2 - Crankcase cat. 1
Crankshaft cat. 2 - Crankcase cat. 2
Crankshaft
Crankshaft
Carter
Carter

DESCRIPTION DIMENSIONS INITIALS

INITIALS

A

A

A

Type A -red

Type B - blue

Type C - yellow

Category 1

Category 2

Category 1

Category 2

QUANTITY

0,15 ÷ 0,30

0,20 ÷ 0,40

0,20 ÷ 0,40

QUANTITY

1,970 ÷ 1,973

1,973 ÷ 1,976

1,976 ÷ 1,979

C - C

B -B

B - B

A -A

28,998 ÷ 29,004

29,004 ÷ 29,010

32,959 ÷ 32,965

32,953 ÷ 32,959

24

FITTING CLEARANCE

Driving shaft/case axial clearance: Standard clearance 0,15 ÷ 0,40mm (cold engine).

CARNCSHAFT - CRANKCASE AXIAL CLEARANCE/CARTER

NAME

Half shaft transmission side
Half shaft flywheel side
Conecting rod
Spacing tool

DESCRIPTION DIMENSIONS INITIALS

16,6+0- 0,05

16,6+0- 0,05

18- 0,10-0,15

51,4+0,05

A

B

C

D

QUANTITY

D = 0,20 ÷ 0,50

D = 0,20 ÷ 0,50

D = 0,20 ÷ 0,50

D = 0,20 ÷ 0,50

25

SLOT PACKING SYSTEM

Characteristics

Compresion ratio - 125cc verion
Rc: 11,50÷13:1

The length «A» to be measured refers to the pistón protrusion. It indicates the amount by which the surface formed
by the pistón crown tops the surface formed by the upper parí of the cylinder. The more the pistón descends into the
cylinder, the less the base gasket to be applied (to recover the compression ratio) will be and vice versa.

N.B.

THE MEASUREMENT OF «A» MUST BE CARRIED WITH THE PISTÓN AT THE TDC, WITHOUT ANY GASKET
INSTALLED BETWEEN THE CRANKCASE AND THE CYLINDER, AND AFTER RESETTING THE COMPARATOR,
COMPLETE WITH SUPPORT, ON A RECTIFIED SURFACE.

125CC VERSIÓN WITH FIBRE HEAD GASKET (1.1)

NAME

Thicknesses 125
Thicknesses 125

MEASURE A THICKNESS

2,20÷2,45

2,45÷2,70

0,4 ± 0,05

0,6 ± 0,05

26

SLOT PACKING SYSTEM

Characteristics

Compresion ratio - 125cc verion
Re: 11,50÷13:1

The length «A» to be measured refers to the pistón protrusion. It indicates the amount by which the surface formed
by the pistón crown tops the surface formed by the upper part of the cylinder. The more the pistón descends into the
cylinder, the less the base gasket to be applied (to recover the compression ratio) will be and vice versa.

N.B.

THE MEASUREMENT OF «A» MUST BE CARRIED WITH THE PISTÓN AT THE TDC, WITHOUT ANY GASKET
INSTALLED BETWEEN THE CRANKCASE AND THE CYLINDER, AND AFTER RESETTING THE COMPARATOR,
COMPLETE WITH SUPPORT, ON A RECTIFIED SURFACE.

125CC VERSIÓN WITH METALLIC HEAD GASKET (0.3)

NAME

Thicknesses 125
Thicknesses 125

MEASURE A THICKNESS

1,40÷1,65

1,65 ÷1,90

0,4 ± 0,05

0,6 ± 0,05

27

SISTEMA DE MONTAJE DE ESPESORES

Características Técnicas

Relación de compresión versión 250
Re: 10,5-11,5

MEASUREMENT (A)

(WITH PISTON AT T.D.C.)

NOTE

MEASUREMENT (A) MUST BE TAKEN WITHOUT TRIM MOUNTED BETWEEN THE
CASING AND THE CYLINDER, AFTER HAVING PUT THE COMPARATOR TO ZERO,
WITH ITS SUPPORT, ON A FLAT PLANE.

NOTE

MOUNT ACCORDING TO THE
MEASUREMENT (A) OBTAINED

N.B.

THE MEASURE «A» TO TAKE IS A PISTÓN PROTRUSION VALUÉ THAT INDICATES HOW MUCH THE PLAÑE
FORMED BY THE PISTÓN TOP PROTRUDES FROM THE PLAÑE FORMED BY THE TOP OF THE CYLINDER.
THE MORE THE PISTÓN PROTRUDES FROM THE CYLINDER, THE MORE THE BASE GASKET TO APPLY (TO
RECOVER THE COMPRESSION RATIO) AND VICE VERSA.

SHIMMING 250

NAME

Shimming 250
Shimming 250
Shimming 250

MEASURE A THICKNESS

2,60÷2,50

2,50÷2,30

2,30÷2,20

0,4 ±0,05

0,6 ± 0,05

0,8 ± 0,05

28

OVERSIZES

OVERSIZES ENGINE

NAME

Compression lining 1° greater
First uprated scraper ring lining
First uprated scraper ring lining
Second uprated compression lining
Second uprated scraper ring lining
Second uprated scraper ring lining
Third uprated compression lining
Third uprated scraper ring lining
Third uprated scraper ring lining

DESCRIPTION DIMENSION

57,2 x 1

57,2 x 1

57,2x 2,5

57,4 x 1

57,4 x 1

57,4 x 2,5

57,6 x 1

57,6 x 1

57,6 x 2,5

RECOMENDEDS PRODUCTS

DESCRIPTION SPECIFICATIONS

Rear hub oil

Air filter sponge oil

Complex calcium soap grease NLGI 1-2

Engine oil

Brake fluid

Cooling fluid

Grease for driven pulley shaft compensating ring and
mobile driven pulley sliding seat

Grease for steering wheel bearings and pin seats

Oil for four stroke engines

Oil SAE 80W/90 of higher quality than API GL3 Specifications

Mineral oil with specific additives to increase adhesión ISO
VG

Grease (brake command levers, Gas)

Synthetic oil SAE 5W/40 of higher quality than API SJ Specifications

Synthetic fluid SAE J1703, NHTSA 116 DOT 4, ISO 4925

Mono-ethyiene glycol based anti-freeze, CUNA NC 956-16 fluid

Molybdenum bisulphide grease

Lithium soap and zinc oxide grease NLGI2 for the oscillating arm

Oil for flexible transmission lubrication (gas control)

INITIALS

A

A

A

A

A

A

A

A

A

QUANTITY

0,15 ÷ 0,30

0,10 ÷ 0,30

0,15 ÷ 0,35

0,15 ÷ 0,30

0,10 ÷ 0,30

0,15 ÷ 0,35

0,15 ÷ 0,30

0,10 ÷ 0,30

0,15 ÷ 0,35

29