Derbi GP1 50 cc Workshop Manual

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WORKSHOP MANUAL

GP1 50 cc

Page 2

DERBI - NACIONAL MOTOR, S.A., 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 50 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. 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.

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Page 4

INTRODUCTION

GENERAL INFORMATION

GENERAL TECHNICAL DATA

RECOMMENDED TOOLS

REGULAR MAINTENANCE

DISMANTLING

SEAT SIDE TRIM

COWLING

COWLING BOTTOM COVER

WATER-OIL TANK COVER

SIDE COVERS

SHIELD BOTTOM COVER

PETROL TANK COVER

HELMET HOLDER

FOOTRESTS

SIDE COVERS

SHIELD

DIRECT ACCESS TO THE BOTTOM OF THE CARBURETTOR

DISMANTLING FOOTRESTS

EXTRACTING COMPLETE AIR FILTER BOX

DISCONNECTING SECONDARY AIR PIPE

EXTRACTING CARBURETTOR AIR INTAKE PIPE

EXTRACTING CARBURETTOR

Page 1 Page 8 Page 9 Page 18 Page 24

Page 35 Page 35 Page 36 Page 36 Page 36 Page 37 Page 37 Page 38 Page 39 Page 39 Page 39

Page 40 Page 40 Page 40 Page 40 Page 41

THE MACHINE’S ENGINE

DISMANTLING THE ENGINE

TRANSMISSION COVER DISMANTLING DRIVEN PULLEY SHAFT SUPPORT BEARINGS FITTING DRIVEN PULLEY SHAFT SUPPORT BEARINGS

DISMANTLING DRIVEN PULLEY

CHECKING CLUTCH BELL HOUSING

DISMANTLING CLUTCH

CHECKING CLUTCH

BRAKE RETAINING RING DISMANTLING DRIVEN PULLEY HALF BEARINGS CHECKING FIXED DRIVEN HALF PULLEY CHECKING MOBILE DRIVEN HALF PULLEY FITTING DRIVEN HALF PULLEY BEARINGS

CHECKING VARIATOR SPRING

Page 43 Page 43 Page 44 Page 44 Page 45 Page 45 Page 45 Page 46 Page 46 Page 47 Page 47 Page 48 Page 49 Page 49

Page 5

ASSEMBLING CLUTCH

FITTING DRIVEN PULLEY

TRANSMISSION BELT

DISMANTLING DRIVING PULLEY

MIXER GEARING AND BELT

CHECKING ROLLER CONTAINER

FITTING DRIVING PULLEY

FINAL REDUCTION

DISMANTLING ENGINE PINION

DISMANTLING HUB COVER

DISMANTLING OUTPUT PINION SHAFT

DISMANTLING OUTPUT PINION SHAFT BEARING

DISMANTLING DRIVEN PULLEY SHAFT BEARING

CHECKING THE HUB SHAFTS

CHECKING THE HUB COVER FITTING DRIVEN PULLEY SHAFT BEARING FITTING WHEEL PULLEY SHAFT BEARING

FITTING THE HUB COVER

MAGNETO COVER

DISMANTLING THE ENGINE

FITTING THE STATOR

FITTING THE MAGNETO COVER

Page 49 Page 50 Page 50 Page 51 Page 51 Page 51 Page 52

Page 53 Page 53 Page 54 Page 54 Page 54 Page 55 Page 55 Page 55 Page 56 Page 57

Page 57 Page 57 Page 58

MAGNETO AND STARTING

DISMANTLING THE STARTER MOTOR

DISMANTLING THE MAGNETO

CHECKING THE MAGNETO COMPONENTS

FITTING THE MAGNETO

FITTING THE STARTER MOTOR

CYLINDER UNIT AND TIMING

DISMANTLING THE SUCTION COLLECTOR

DISMANTLING THE CYLINDER HEAD

DISMANTLING THE PISTON CYLINDER

CHECKING THE CONNECTING ROD BIG END

CHECKING THE GUDGEON PIN

CHECKING THE PISTON

CHECKING THE CYLINDER

Page 58 Page 58 Page 59 Page 59 Page 60

Page 60 Page 60 Page 61 Page 61 Page 61 Page 62 Page 62

Page 6

CHECKING THE OIL SEALS

FITTING THE PISTON

CHECKING TIMING COMPONENTS

CRANKCASE

OPENING THE CRANKCASE

DISMANTLING THE CRANKSHAFT

DISMANTLING THE MAIN BEARINGS

FITTING THE MAIN BEARINGS

CHECKING THE CRANKSHAFT ALIGNMENT

FITTING THE CRANKSHAFT

REJOINING THE CRANKCASE

LUBRICATION

OIL PUMP

DISMANTLING

FITTING

FUEL SUPPLY

FORKS

SEBAC FORKS

MARZOCCHI FORKS

DISMANTLING THE FRONT SUSPENSION

INSPECTING THE FRONT FORKS

Page 63 Page 63 Page 64

Page 65 Page 65 Page 65 Page 66 Page 67 Page 67 Page 68 Page 69

Page 70 Page 70 Page 71

Page 72 Page 73 Page 74 Page 76

SHOCK ABSORBER AND SWINGING ARM

DISMANTLING

INSPECTION

FRONT WHEEL AND BRAKES

FRONT WHEEL DIAGRAM

DISMANTLING

INSPECTING THE FRONT WHEEL

DISMANTLING THE FRONT DISK CALLIPER

FITTING THE FRONT WHEEL

Page 78 Page 79 Page 79

Page 80 Page 81 Page 81 Page 83 Page 90

Page 7

REAR WHEEL AND BRAKES

REAR WHEEL DIAGRAM

DISMANTLING

DISMANTLING THE REAR DISK CALLIPER

INSPECTING THE REAR WHEEL

REFITTING THE REAR WHEEL

TRANSMISSION

DISMANTLING

INSPECTING THE TRANSMISSION CHAIN

CROWN WHEEL

REFITTING THE CROWN WHEEL AND THE TRANSMISSION CHAIN

COOLING SYSTEM

BLEEDING THE SYSTEM

CHECKING THE WATER PUMP

THERMOSTAT

DISMANTLING

CHECKING

FITTING

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Page 103 Page 103 Page 106 Page 106 Page 106 Page 107

ELECTRICAL SYSTEM

GP1 50C.C. WIRING DIAGRAM

GP1 50C.C. WIRING DIAGRAM (SWITZERLAND)

CHECKING CONNECTORS

STEPS FOR THE INSPECTION

DIGITAL INSTRUMENTS UNIT

IGNITION

AUTOMATIC CHOKE AND LIGHTS

BATTERY RECHARGE AND STARTING

LEVEL INDICATORS

TURN INDICATORS AND HORN

CHECKS AND CONTROLS

CHECKING PICK-UP

REFITTING IGNITION

Page 108 Page 109 Page 110 Page 111

Page 111 Page 112 Page 113 Page 114 Page 115 Page 116 Page 117 Page 117 Page 118

Page 8

CHECKING THE STATOR

CHECKING THE VOLTAGE REGULATOR

OPERATIONS

FUSES

DISMANTLING THE BATTERY

BATTERY-INITIAL CHARGE

CAPACITY

INSPECTING THE CHARGING CONDITIONS

RECHARGING

CHECKING THE ELECTRICAL SYSTEM

TROUBLESHOOTING

ENGINE

REAR WHEEL TURNS WITH ENGINE TICKING OVER

DIFFICULTY STARTING

EXCESSIVE CONSUMPTION OF OIL/SMOKY EXHAUST

THE ENGINE TENDS TO STOP AT FULL THROTTLE

THE ENGINE TENDS TO STOP WHEN TICKING OVER

HIGH FUEL CONSUMPTION

EXCESSIVELY NOISY EXHAUST

ENGINE OVERHEATING

FAULTS

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Page 128 Page 129 Page 129 Page 130 Page 130 Page 130 Page 131 Page 131 Page 131 Page 132

TRANSMISSION AND BRAKES PULLING OR ABNORMAL CLUTCH OPERATION

POOR BRAKING POWER

BRAKES OVERHEATING

ELECTRICAL WIRING

STEERING AND SUSPENSION – REAR WHEEL

STIFF STEERING

TOO MUCH PLAY IN STEERING

NOISY SUSPENSION

SUSPENSION LEAKING OIL

Page 132 Page 133 Page 133 Page 134 Page 134 Page 135 Page 135 Page 135 Page 136

Page 9

REGULATIONS

GU O S

SGUOS

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.

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c.c.

MACHINE ENGINE PREFIX FRAME PREFIX

GP1

GP1 50 c.c.

C451M

DIMENSIONS AND WEIGHT

VTHPR1A1A

CHARACTERISTIC

Maximum length Maximum height Length between axles Handlebar width Handlebar height Total weight of machine

ENGINE

CHARACTERISTIC

Engine type Diameter per stroke Cubic capacity Compression ratio Carburettor CO regulation Tick over Air filter Ignition system Lubrication

DIMENSION/VALUE

1875 mm. 1212 mm. 1338 mm. 705 mm. 1050 mm. 117 kg.

DIMENSION/VALUE

Single cylinder 2-stroke 40 x 39.3 mm

49.40 cm3

11. 3 ÷ 12.8 :1 DELL’ORTO PHVA 17,5 ID

3.5%±0.5 1800 ÷ 2000 rpm Sponge soaked in oil for filters. Electric starter motor. Carried out using the mixture oil, and variable depen-

ding on the engine revs and the throttle butterfly valve aperture by means of a pump driven by the crankshaft by way of a toothed belt.

Page 11

ENGINE

CHARACTERISTIC

Alimentación

Sistema de refrigeración Embrague Piñón salida cambio Plato de arrastre

TRANSMISSION

CHARACTERISTIC

Transmission

CAPACITY

CHARACTERISTIC

DIMENSION/VALUE

Depression fuel pump supplying lead free petrol via the carburettor.

By forced circulation of liquid. Dry automatic centrifugal Z 19 Z 45

DIMENSION/VALUE

Automatic speed variator with expandable pulleys, trapezoidal belt, automatic clutch, gear reducer.

DIMENSION/VALUE

Fuel tank capacity Fuel reserve capacity Oil tank capacity Oil reserve capacity Cooling system capacity

ELECTRICAL SYSTEM

CHARACTERISTIC

Ignition system

Ignition advance (before T.D.C.) Spark plug Battery Main fuse

7.7 l

2.7 l

1.75 l

0.25 l

1.0 l

DIMENSION/VALUE

Electronic 12v 88 W with central intermittence unit + check control

17º a 4000 rpm CHAMPION RN1C 12 V 6 Ah

7.5 A

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FRAME AND SUSPENSIONS

CHARACTERISTIC

Frame Front suspension Diameter / Travel Oil capacity Oil type Rear suspension Travel

BRAKING SYSTEM

CHARACTERISTIC

Front brake Front disk diameter Rear brake Rear disk diameter Brake fluid type

DIMENSION/VALUE

Aluminium, Delta Box type Telescopic forks with inverted bars 35 mm / 80 mm 95 c.c. SAE 7,5 W Swinging arm with single shock absorber. 80 mm

DIMENSION/VALUE

Hydraulically operated disk 245 mm Hydraulically operated disk 180 mm DOT 4

WHEELS AND TYRES

CHARACTERISTIC

Front wheel type Front tyre inflated pressure. Rear wheel type Rear tyre inflated pressure

CARBURETTOR

CHARACTERISTIC

Type Diameter of diffuser Main jet Minimum air jet Carburettor needle setting Needle position (slots from above)

DIMENSION/VALUE

120 / 70 x 14in (tubeless) 190 kPa / 200 kPa (with pillion passenger) 140 / 60 x 14in (tubeless) 200 kPa / 220 kPa (with pillion passenger)

DIMENSION/VALUE

DELL’ORTO PHVA 17.5 ID Ø 17.5 mm 53 Ø 1.5 mm A22 1

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CARBURETTOR

CHARACTERISTIC

Emulsifier Idle jet Minimum air jet Secondary minimum air orifice Minimum mixture screw initial opening Choke jet Choke air jet Choke needle travel Fuel entry orifice

DIMENSION/VALUE

209HA 32 Libre Ø 2.5 mm 1 1/2 50 Ø 1.5 mm 11 mm Ø 1.0 mm

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CHASSIS TIGHTENING TORQUES

DESCRIPTION

Top shock absorber - chassis securing device M10x150 8.8 Bottom shock absorber – engine securing device M10x150 8.8 Engine Silent bloc – chassis securing device M10x150 8.8 Engine support securing bolt M10x150 8.8 Engine rear – support securing device M8x125 8.8 Engine rear support - chassis securing device M10x150 8.8 Engine rear Silent bloc clamp securing device M6x100 8.8 Swinging arm securing device M14x200 Change output pinion bush securing device M16x125 Change output pinion securing device M35x100 Filter box – engine securing device M6x100 Horn – chassis securing device M6x100 Steering forks – chassis securing device M24x100 Exhaust pipe –cylinder securing device M6x100 8.8 Exhaust pipe –crankcase securing device M8x125 8.8 Steering lock – chassis securing device M6x100 8.8 Handlebars – steering forks securing device M6x100 8.8 Handlebar clamp securing device M8x125 8.8 Counterweight- handlebars securing device M5x80 8.8 Front wheel – forks securing device M14x200 Fork arm lock securing device M8x125 Brake disk – front wheel securing device M6x100 Brake disk calliper – forks securing device M10x1.5 Rear wheel securing device M14x200 Drag plate – wheel securing device M6x100 10.9 Brake disk – rear wheel securing device M8x125 10.9 Prop stand – chassis securing device M8x125 Brake puller securing device M10x150 10.9 Gripper – chassis securing device M8x125 8.8 Radiator - chassis securing device M6x100 Various metal elements to chassis securing device M5x80 Various metal elements to chassis securing device M6x100 Various metal elements to chassis securing device M8x125 Various plastic elements to chassis securing device M6x100 Various plastic elements to chassis securing device M6x100

TORQUES (N.M)

30 ÷ 40 30 ÷ 40 30 ÷ 40 20 ÷ 30

17 ÷ 19

30 ÷ 40

8 ÷ 10

70 ÷ 80 115 ÷ 125 115 ÷ 125

8 ÷ 10 8 ÷ 10

90 ÷ 130

9 ÷ 12

17 ÷ 19

8 ÷ 10 17 ÷ 19 17 ÷ 19

3.5 ÷ 4.5 35 ÷ 50

15 ÷ 19

8 ÷ 10 35 ÷ 40 70 ÷ 80 10 ÷ 12 25 ÷ 29

15 ÷ 19

35 ÷ 40

17 ÷ 19

8 ÷ 10

3.5 ÷ 4.5 8 ÷ 10

15 ÷ 19

1 ÷ 2

2 ÷ 3.5

TORQUES (M.KG)

3 ÷ 4 3 ÷ 4 3 ÷ 4 2 ÷ 3

1.7 ÷ 1.9 3 ÷ 4

0.8 ÷ 1 7 ÷ 8

11.5 ÷ 12.5

0.8 ÷ 1

9 ÷ 13

0.9 ÷ 1.2

1.7 ÷ 1.9

0.8 ÷ 1

1.7 ÷ 1.9

0.35 ÷ 0.45

3.5 ÷ 5

1.5 ÷ 1.9

0.8 ÷ 1

3.5 ÷ 4 7 ÷ 8

1 ÷ 1.2

2.5 ÷ 2.9

1.5 ÷ 1.9

3.5 ÷ 4

1.7 ÷ 1.9

0.8 ÷ 1

0.35 ÷ 0.45

0.8 ÷ 1

1.5 ÷ 1.9

0.1 ÷ 0.2

0.2 ÷ 0.35

SEALER

•

Page 15

ENGINE TIGHTENING TORQUES

DESCRIPTION

Clutch bell housing nut Clutch locking nut Nut for locking the driving pulley on the crankshaft Kick start lever bolt Magneto nut Magneto fan bolts Crankcase halves joining bolts Bolts for securing exhaust pipe to the crankcase Bolts for securing the filter box to the crankcase Cylinder head nuts Starter motor bolts Spark plug Oil sump drain plug Rear hub cover bolts

DESCRIPTION

Transmission cover bolts Suction collector bolts Magneto cover securing bolts Cylinder casing securing bolts Stator securing bolt Pick-up securing bolt Mixer securing bolt Bolt securing brake pedal to shaft in the engine

TORQUES (N.M) TORQUES (M.KG)

40 ÷ 44 55 ÷ 60 40 ÷ 44

12 ÷ 13

40 ÷ 44

3 ÷ 4

12 ÷ 13

22 ÷ 24

4 ÷ 5 10 ÷ 11 12 ÷ 13

25 ÷ 30

3 ÷ 5 12 ÷ 13

TORQUES (N.M) TORQUES (M.KG)

12 ÷ 13

8 ÷ 9

1 ÷ 2

3.5 ÷ 5 3 ÷ 4 4 ÷ 5 3 ÷ 4

12 ÷ 13

4 ÷ 4.4

5.5 ÷ 6 4 ÷ 4.4

1.2 ÷ 1.3 4 ÷ 4.4

0.3 ÷ 0.4

1.2 ÷ 1.3

2.2 ÷ 2.4

0.4 ÷ 0.5

1 ÷ 1.1

1.2 ÷ 0.3

2.5 ÷ 3

0.3 ÷ 0.5

1.2 ÷ 1.3

0.8 ÷ 0.9

0.1 ÷ 0.2

0.35 ÷ 0.5

0.3 ÷ 0.4

0.4 ÷ 0.5

0.3 ÷ 0.4

1.2 ÷ 1.3

Page 16

CONECTION PISTON AND CYLINDER

NAME

Standard fitting Standard fitting Standard fitting Standard fitting 1st oversize fitting 1st oversize fitting 1st oversize fitting 1st oversize fitting 2nd oversize fitting 2nd oversize fitting 2nd oversize fitting 2nd oversize fitting

PLAY

<⁄> <⁄> <⁄> <⁄> <⁄> <⁄> <⁄> <⁄> <⁄> <⁄> <⁄> <⁄>

INITIALS

M N O

P M1 N1 O1

P1 M2 N2 O2

CYLINDER

39,997-40,004 40,004-40,011 40,011-40,018 40,018-40,025 40,197-40,204 40,204-40,211

4,211-40,218 40,218-40,225 40,397-40,404

40-404-40,411

40-411-40,418

40,418-40,425

PISTON

39,943-39,95

39,95-39,957 39,957-39,964 39,964-39,971

40,143-40,15

40,15-40,157 40,157-40,164 40,164-40,171

40,343-40,35

40,35-40,357 40,357-40,364 40,364-40,371

PLAY ON FITTING

0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061 0,047-0,061

PISTON RINGS

NAME

Compression lining Compression lining 1˚ Greater Compression lining 2˚ Greater

DESCRIPTION

DIMENSIONS

40 40,2 40,4

INITIALS

A A A

QUANTITY

0,10 ÷ 0,25 0,10 ÷ 0,25 0,10 ÷ 0,25

Page 17

END PLAY BETWEEN CRANKCASE, CRANKSHAFT AND CONNECTING ROD

PACKING S

YSTEM

NAME

Connecting rod

onnecting rod

Packing washer

acking washer

Half shaft transmission side

lf shaft transmission si

Half shaft flywheel side

alf shaft flywheel sid

Spacing between shoulders

pacing between shoulders

Cage

DESCRIPTION

DIMENSIONS

11,75 0 ÷ 0, 0 5

0,5 ÷ 0,03

13,75 ÷ 0,040

40,64

11,80 ÷ 0,35

INITIAL

QUANTITY

Play E=0,25÷0,50

Play F= 2,20÷0,75

Play E=0,25÷0,50

Play F= 2,20÷0,75

Play E=0,25÷0,50

Play F= 2,20÷0,75

Play E=0,25÷0,50

Play F= 2,20÷0,75

Play E=0,25÷0,50

Play F= 2,20÷0,75

SLOT PACKING SYSTEM

- Fit the cylinder without positioningthe base gasket

- Position a dial gauge on the special tool and zeri it on rectified surface.

- Fis the tool on the top of the cylinder using two nuts to fix it to the studs and then bring the piston to T.D.C.

- The gasket thickness to be adopted varies with the measurement. For this reason gaskets with three different thicknesses ara available as spares.

Specific tooling

020272Y Tool for checking the piston of the piston.

Page 18

SISTEMA DE MONTAJE DE ESPESORES

Packing Packing Spacing

NAME

MEASURE A

2,80 ÷ 3,04 3,04 ÷ 3,24 3,24 ÷ 3,48

THICKNESS

0,4 0,6 0,8

Page 19

PPREPARATION FOR REMOVAL AND DISMANTLING

FOR REMOVAL AND DISMANTLING

1. Remove all the dirt, grime, dust and other foreign material

before removing and dismantling.

2. Use properly cleaned tools and equipment.

See “SPECIAL TOOLS”.

3. On dismantling the motorcycle, always keep paired parts together. This includes gears, cylinders, pistons and other parts submitted to natural wear in pairs. Paired parts must always be reassembled or replaced together.

4. While dismantling the motorcycle, clean all the parts and lay them out on trays in the order dismantled. This speeds up reassembly and ensures the correct fitting of all the parts.

5. Keep all parts away from any contact with fire.

Page 20

REPLACEMENT PARTS

C S

RETAINING RINGS AND O RINGS

/SC SS S S

GS G GS

1. Use only genuine DERBI spare parts. For all lubrication

tasks use oils and greases recommended by DERBI. Other makes make seem similar in their function and appearance, but are inferior in quality.

SEALS, RETAINING RINGS AND O-RINGS

1. Replace all seals, retaining rings and O-rings when servi-

cing the engine. All surfaces receiving seals, retaining ring edges and O-rings must be cleaned.

2. Apply oil to all paired parts and bearing during reassembly. Apply grease to the retaining ring edges.

TAB/SPACER WASHERS AND SPLIT PINS

1. After removing them, replace all tab/spacer washers (1)

and split pins Bend the tabs to fit the flat surfaces of the bolt or nut once they have been tightened to the specified torque.

BEARINGS AND RETAINING RINGS

1. Fit bearings and retaining rings in such a way that the ma-

nufacturers marks remain visible. On fitting retaining rings, applying a thin film of light lithium soap based grease to their edges. Where required, apply oil generously when fitting bearings.

WARNING

DO NOT USE COMPRESSED AIR TO DRY BEARINGS. THIS DAMAGES THE BEARING SURFACES.

Page 21

LOCKING RINGS

OC G GS

TOOLS

1. Examine all the locking rings carefully before fitting.

Always replace the gudgeon pin circlips after every use. Replace distorted locking rings. On fitting a locking ring (1), ensure that the sharp edge (2) is on the opposite side to the force to be applied to it.

See the figure on the side, (4) Axle.

SPECIAL TOOLS

1. The following special tools are needed for assembly and

for complete and exact adjustments. Only use the proper special tools; thereby avoiding damage caused by the use of unsuitable tools or improvised techniques.

005095Y

001467Y

002465Y

STORES CODE

Engine support

Bell

Pliers for snap rings

IMAGEDESCRIPTION

020150Y

Support for air heater

Page 22

STORES CODE

IMAGEDESCRIPTION

020151Y

020162Y

020163Y

020164Y

020451Y

Air heater

Flywheel extractor

Crankc splitting plate

Half-pulleys fixing sheath

Starter sprocket retainer

020166Y

020163Y

020167Y

Piston rings fixing tool

Bearing fitting stand

Impeller retaining spanner

Page 23

REFERENCIA

IMAGENDESCRIPCIÓN

020168Y

020169Y

020170Y

020325Y

020331Y

Oil seal fitting drift on half crankcase

Water pump drive shaft spanner

Extractor engagement sends mixer

Pliers for brake-shoe springs

Digital multimeter

020332Y

020334Y

020335Y

Digital rpm counter

Multiple battery charger

Magnetic stand and comparator

Page 24

REFERENCIA

IMAGENDESCRIPCIÓN

020350Y

020656Y

020340Y

020080Y

020168Y

Electric system diagnostic device

Compass flywheel stop spanner

Crankshaft sela punch

Needle bearing punch

Crankcase-half water-seal assembly punch

020341Y

020342Y

00G05300131

Piston ring assembly tool

Compressor crankshaft pulley retaiting tool

Change output pinion tool

Page 25

MAINTENANCE CHART

C C

2 YEARS

BEFORE EVERY START-UP

ACTION

Check the oil level Check the brake fluid level Check the coolant level Check wear on brake pads/shoes Check light mechanism operation Check horn operation Check chain tension Check tyre pressure and wear Check for possible fluid leaks (petrol, oil, coolant, brake fluid) Check for possible cracks in the fuel pipes Check that all the control elements are operating correctly Check that the brakes are operating correctly

AFTER EVERY WASHING

ACTION

Clean and lubricate the chain Lubricate the clutch and brake levers Check that the brakes are operating correctly Spray locks and light switches with anti-damp spray

EVERY 1,000 km

ACTION

Clean and lubricate the chain

EVERY 2 YEARS

ACTION

Brake fluid - Change Cooling fluid - Replacement

Page 26

ACTION

Hub oil - Replacement Oil mixter / Throttle linkage - Adjust Speedometer cable - Grease Steering - Adjust Brake levers - Grease Brake fluid level - Check Nuts, bolts and fasteners - Check Electrical system and battery - Check Tires-inflation and wear - Check Vehicle and brake test - Road test

AT 5000 KM OR 12 MONTHS, 25000 KM, 35000 KM AND 55000 KM

ACTION

Hub oil level - Check Spark plug / Electrode gap - Change Air filter - Cleaning Oli mixter / Throttle linkage - Adjust Cooling fluid level - Check Brake levers - Grease Brake pads - Check condition + wear Brake fluid level - Check Electrical system and battery - Check Tires-infaltion and wear - Check Vehicle and brake test - Road test

AT 1000 KM OR 4 MONTHS

Page 27

AT 10000 KM OR 24 MONTHS AND 50000 KM

ACTION

Hub oil - Replacement Spark plug / spark gap - Replacement Air filter - Cleaning Idle speed / Fuel - Adjust Oil mixer / Throttle linkage - Adjust Variators rollers - Change Speedometer cable - Grease Transmition Belt - Check Cooling fluid level - Check Steering - Adjust Brake levers - Grease Brake pads - Check condition + wear Brake fluid level - Check Transmissions - Lubricate Nuts, bolts and fasteners - Check Suspensions - Check Headlight - Adjust Tires-inflation and wear - Check Vehicle and brake test - Road test

ACTION

Hub oil level - Check Spark plug / spark gap - Replacement Air filter - Cleaning Oil mixer / throttle linkage - Adjust Transmission Belt - Replacement Cooling fluid level - Check Brake levers - Grease Brake pads - Check condition + wear Brake fluid level - Check Electrical system and battery - Check Tires-inflation and wear - Check SAS bos (esponge) - Cleaning Vehicle and brabe test - Road test

AT 15000 KM AND 45000 KM

Page 28

AT 20000 KM AND 40000 KM

ACTION

Hub oil - Replacement Spark plug / electrode gao - Change Air filter - Cleaning Idle speed / Fuel - Adjust Cylinder cooling system - Check / Clean Oil mixer / throttle linkage- Adjust Transmission Belt - Check Variatos roller - Change Fuel-oil mixer belt - Change Cooling fluid level - Check Radiator - External cleaning / Check Speedometer cable - Grease Steering - Adjust Brake levers - Grease Brake pads - Check condition + wear Brake fluid level - Check Transmisions - Lubricate Nuts, bolts and fasteners - Check Suspensions - Check Electrical system and battery - Check Headlight - Adjust Tires-inflation and wear - Check Vehicle and brake test - Road test

ACTION

Hub oil - Replacement Spark plug / spark gap - Replacement Air filter - Cleaning Idle speed / Fuel - Adjust Oil mixer / throttle linkage - Adjust Transmission Belt - Replacement Variatos roller - Change Cooling fluid level - Check Speedometer cable - Grease Steering - Adjust Brake levers - Grease Brake pads - Check condition + wear

AT 30000 KM

Page 29

ACTION

Braking circuit hose - Replacement Brake fluid level - Check Transmisions - Lubricate Buts, bolts and fasteners - Check Suspensions - Check Electrical system and battery - Check Headlight - Adjust Tires-inflation and wear - Check SAS box (esponge) - Clean Vehicle and brake test -Road test

ACTION

Hub oil - Replacement Spark plug / spark gap - Replacement Air filter - Cleaning Idle speed / Fuel - Adjust Oil mixer / throttle linkage - Adjust Transmission Belt - Replacement Variatos roller - Change Fuel-oil mixter belt - Change Cooling fluid level - Check Radiator - External cleaning / check Speedometer cable - Grease Steering - Adjust Brake levers - Grease Brake pads - Check condition + wear Braking circuit hose - Replacement Brake fluid level - Check Transmissions - Lubricate

Nuts, bolts ans fasteners - Check Suspensions - Check Electrical system and battery - Check Headlight - Adjust Tires-inflation and wear - Check SAS box (esponge) - Clean Vehicle and barake test - Road test

AT 30000 KM

AT 60000 KM

Page 30

SPARK PLUG

PLUG

- Rest the vehicle on its centre-stand;

- Detach the spark plug flap by removing the two fixing screws;

- Detach the H.T. cable cap from the spark plug;

- Remove the spark plug using the box-spanner provided;

- Examine the conditions of spark plug, the integrity of the insulator, and measure the spark gap with the aid of a feeler gauge.

- If required, adjust the spark gap by carefully bending the outer electrode. In the event of defects, replace the spark plug with one of the recommended type;

- Engage the thread, with the correct inclination, and the screw the spark plug by hand as far as it will go, then tighten it using the box-spanner provided;

- Inserí the spark plug cap;

- Refit the spark plug flap.

CAUTION

THE SPARK PLUG REMOVAL MUST BE CARRIED OUT WITH THE ENGINE COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5,000 KM. THE USE OF NON APPROVED ELECTRONIC 1GNITION DEVICES OR SPARK PLUGS OTHER THAN THE PRESCRIBED MODEL MAY SERIOUSLY DAMAGE THE ENGINE.

CHARACTERISTIC

Spark plug

CHAMPION RN1C

Electrode gap

0.45-0.55 mm

Locking torques (N.m)

Spark plug 25 - 30 N.m

Page 31

HUB OIL

OIL

Check

To check the level, proceed as follows:

1) Rest the vehicle onto its centre-stand, on flat ground;

2) Remove dipstick «A»; dry it with a clean cloth and reinsert it, using the whole thread;

3) Remove the dipstick and check the oil mark reaches just below the second notch from the bottom;

4) Screw the dipstick back in with the correct torque.

Oil synthetic multidegree SAE 75W/85 API GL4

Replacement

- Remove oil filler cap «A».

- Loosen oil draining cap «B» and allow for the system to drain completely.

- Refit the draining cap and refill the hub with the prescribed oil.

Characteristic

Rear hub oil

85c.c.

Page 32

AIR FILTER

- Remove the cleaner plug by unloosing the 6 fixing screws. Remove the filtering element.

Cleaning:

-Wash with water and neutral soap.

-Dry with a clean cloth and small jets of compressed air.

-Soak with a 50 fuel/oil mixture.

-Let the filtering element drain and then squeeze it with your hands without crushing it.

-Let it dry and refit it. Mineral oil with special additives to increase its adhesiveness ISO VG 150

CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAT OF THE PISTON AND CYLINDER

Recommended products

Mineral oil with specific additives to increase adhesion ISO VG 150

Page 33

CHECKING THE IGNITION TIMING

THE IGNITION TIMING

Adjust the control cables: Mixer cable: see “Mixer timing” procedure, below.

Throttle cable:

Adjust the screw on the carburettor so that there is no play on the sheath.

Splitter control cable: Adjust the screw on the throttle grip on the handlebar so that there is no play on the twist grip.

All cables must be adjusted so that there is no play on their sheaths.

Mixer timing

- Adjust via the transmission screw on the crankcase, with the throttle cable released, the reference machined on the rotating plate which must be aligned to that shown on the mixer body as indicated in the figure.

While performing this operation the engine must be fed with a 2 oil-fuel mixture (at least 0.5 litres if the tank is empty).

CAUTION

WHEN RUNNING OUT OF OIL OR REMOVING THE OIL TANK, FOLLOW THE MIXER BLEEDING OPERATIONS AS FOLLOWS: REFILL THE OIL TANK, WITH THE MIXER FITTED ONTO THE ENGINE, AND THE ENGINE NOT RUNNING, DETACH THE MIXER TUBE FROM THE CARBURETTOR AND LOOSEN THE BLEED SCREW (SEE ARROW IN FIGURE) UNTIL OIL STARTS FLOWING OUTWARDS. RECONNECT THE INLET TUBE TO THE CARBURETTOR, FIXING IT WITH THE APPROPRIATE METALLIC CLAMP.

Recommended products

Synthetic oil that passes API TC ++ specifications

Page 34

BRAKING SYSTEM

SYSTEM

Level check

Proceed as follows:

- Rest the vehicle onto its centre-stand and align the handlebars;

- Check the liquid level through the inspection hole «A».

A certain decrease in the liquid level is due to the wear of the pads.

Top-up

Use the following procedure: Loosen the two screws, remove the reservoir cap, remove the gasket and top up only with the prescribed fluid without exceeding the maximum level.

CAUTION

USE ONLY DOT 4 BRAKE FLUID.

CAUTION

KEEP THE BRAKE FLUID AWAY FROM THE SKIN, THE EYES AND CLOTHING. IN CASE OF CONTACT, RINSE GENEROUSLY WITH WATER.

CAUTION

THE BRAKE FLUID IS HIGHLY CORROSIVE. TAKE CARE NOT TO SPILL IT ON THE PAINTWORK.

CAUTION

THE BRAKE FLUID IS HYGROSCOPIC, I.E. IT ABSORBS HUMIDITY FROM THE AIR. IF THE HUMIDITY CONTAINED IN THE FLUID EXCEEDS A GIVEN CONCENTRATION, THE BRAKING ACTION BECOMES INSUFFICIENT.

NEVER DRAW THE FLUID FROM OPEN OR PARTLY EMPTY CONTAINERS.

UNDER NORMAL CLIMATIC CONDITIONS THE FLUID SHOULD BE RENEWED EVERY 20,000 KM, OR IN ANY CASE EVERY TWO YEARS.

N.B.

CHANGE THE BRAKE FLUID AND BLEED THE SYSTEM AS DESCRIBED IN CHAPTER BRAKING SYSTEM

Recommendede products

Synthetic fluid SAE J 1703 NHTSA 116 DOT 4, ISO 4925

Page 35

HEADLIGHT ADJUSTMENT

ADJUSTMENT

Proceed as follows:

1. Position the vehicle in riding conditions, and with the tyres inflated at the prescribed pressure, on a horizontal surface 10m away from a half-lit white screen, ensuring the vertical axis of the vehicle is perpendicular to the screen;

2. Turn on the headlight and check the distance between the ground and the horizontal line which separates the lit area from the dark region, is no more than 9/10 and not less than 7/10 of the height of the headlight, measured from the ground;

3. If this is not the case, adjust the headlight via screw «A», which may be reached by removing the front grid.

WARNING

THE PROCEDURE DESCRIBED ABOVE COMPLIES WITH THE “EURONORM” CONCERNING THE MAX. AND MIN. HEIGHT OF THE LIGHT BEAM OF A ROAD VEHICLE. PLEASE CHECK WITH THE LOCAL AUTHORITIES FOR WHAT REQUIREMENTS MUST BE FULFILLED IN EVERY SINGLE COUNTRY WHERE THE VEHICLE IS TO BE USED.

Page 36

1. SEAT SIDE TRIM

• Extract the 3 securing screws (2 Philips 3.6x14 selftappers and one 5x16 Allen M3) from each cover.

Time taken:

4 Minutes

2. COWLING

• Extract the 6 screws (5x12 Allen M3) from under the cowling.

Time taken:

15 Minutes

• Extract the 8 top screws (Philips 3.6x14 self-tappers with washer) and the 2 side screws (Philips 6x16 with washer).

• Pull the cowling backwards slightly to access the turn indicator connections and disconnect them.

• Extract the cowling backwards.

N.B.

TO REPLACE THE PILOT LIGHTS IT IS ONLY NECESSARY TO EXTRACT THE TWO PILOT LIGHT SCREWS.

Page 37

3. LOWER COWLING COVER

• Extract the 2 securing screws (Philips 6x16 with washer)

Time taken:

17 Minutes

N.B.

TO CONTINUE WITH THE HELMET HOLDER WE NEED TO CONTINUE DISMANTLING THE FRONT PART, SINCE THE PETROL TANK FRONT BREATHER PIPE PASSES THROUGH THE HELMET HOLDER.

4. WATER-OIL TANK COVER

• Extract the 2 top screws (Philips 5x12).

Time taken:

19 Minutes

5. SIDE COVERS

• Pull them gently backwards.

Time taken:

20 Minutes

Page 38

6. SHIELD INNER COVER

• Extract the 2 screws (5x12 Allen M3).

• Extract the 3 top screws (2 Philips 3.6x14 self-tappers and one6x16 Allen screw with washer).

Time taken:

23 Minutes

7. PETROL TANK COVER

• Extract the bottom covers (left and right), by removing the 6 screws (Philips 5x16 with washer) and the two air inputs, 3 screws (1 Philips 3x10 self-tapper, 1 Philips

3.6x10 self-tapper and 1 Philips 5x16), as there are 2 screws (Philips 6x16 with washer) that are inaccessible without carrying out this step.

Time taken:

27 Minutes

Page 39

• After extracting the 6 side screws and the central one (Allen M3 5x12) from the tank cover, lift the front of this removing the 2 lugs, and then remove the back part as in the image.

Time taken:

35 Minutes

ATTENTIÓN

TO PREVENT THE SHIELD FROM DROPPING, THE USE OF A UNEX CLAMP OR SIMILAR IS RECOMMENDED.

8. HELMET CARRIER

• Remove the battery and cables.

• Extract the 6 securing screws (2 Philips 8x45, 2 Philips 6x19 with washer and 2 8x25 bolts), the petrol tank cover, the breather pipe and the seat opening cable.

Time taken:

47 Minutes

Page 40

9. FOOTRESTS

• Remove the 5 securing screws (2 Philips 6x16 with large washer, 2 Philips 6x16 with small washer and 1 Philips 4.8x25 self-tapper), and the one joining the two fairings.

Time taken:

53 Minutes

10. SIDE COVERS

• Remove the 2 securing screws (1 Philips 6x16 with l washer and 1 Philips 3.6x10 self-tapper), and the turn indicator wire.

Time taken:

60 Minutes

11. S H IELD

• Remove the helmet carrier.

• Extract the securing screw (Philips 6x16 with washer).

Time taken:

64 Minutes

N.B.

CUT THE CLAMP USED TO HOLD THE SHIELD.

Page 41

1. DISMANTLING FOOTRESTS

• See step 9 of the dismantling guide.

2. EXTRACTING COMPLETE FILTER BOX

• Extract the 4 (front ) ALLEN Ø 5 screws.

• Extract Ø 6 screw (top rear) with back nut.

3. DISCONNECT THE SECONDARY AIR PIPE.

4. EXTRACT CARBURETTOR AIR INLET PIPE

• Cut the pipe flange (accessing as in the image).

N.B.

TO FIT, IT IS RECOMMENDED LEAVING THE CLAMP UNTIGHTENED IN POSITION ON THE FILTER BOX TO CARBURETTOR AIR PIPE

Page 42

5. Remove the water pipe to the carburettor from the

supporting tab and pull out the filter, starting at the rear.

6 EXTRACT CARBURETTOR

• Loosen the clamp using a ratchet-type tool.

• Disconnect the choke cable, petrol pipe and air inlet pipe from the carburettor. Next, turn it and extract the top cover.

Page 43

• Extract the carburettor to gain access to all its parts.

N.B.

FIT IN REVERSE ORDER, TAKING SPECIAL CARE WITH THE WIRING (PETROL, OIL, WATER).

Page 44

DISMANTLING THE MACHINE’S ENGINE

THE MACHINE S ENGINE

AUTOMATIC

1) Disconnect the battery.

2) Completely remove the exhaust pipe.

3) Remove the rear wheel.

4) Disconnect the electrical wiring from the magneto.

5) Disconnect the throttle and mixer activating transmissions.

6) Disconnect the oil pipes from the mixer, the carburettor and the pump depression control on the carburettor.

7) Disconnect the H.T. cable from the spark plug.

8) Remove the spring from the left hand front part of the Silent bloc.

9) Remove the Allen bolt from the right hand front part of the Silent bloc.

10) Remove the two bolts and corresponding nuts securing the rear of the engine.

AUTOMATIC TRANSMISSION

- Lossen the 15 screws and remove the transmission cover with the aid of a mallet.

N.B.

THE CRANKCASE IS RESTRAINED BY THE TIGHT FITTING BETWEEN THE SHAFT OF THE DRIVEN HALF-PULLEY AND THE BEARING HOUSED ONTO THE CRANKCASE.

Page 45

Meters

THE DRIVEN PULLEY SHAFT BEARING

G U S G

Lithium soap grease, NLGI 33

- Remove the split ring positioned on the external side of the transmission cover.

- Remove the drive gear from its housing, de- creasing the tension that the toothed segment applies via the spring; to do so, it is necessary to slightly rotate the toothed segment (see figure).

CAUTION

WHEN REMOVING THE GEAR, PAY PARTICULAR ATTENSION TO THE LOADING OF THE SPRING AS THIS MAY BE DANGEROUS FOR THE OPERATOR.

REMOVING THE DRIVEN PULLEY SHAFT BEARING

- Slightly heat the crankcase on the inside to avoid damaging the painted surface. Remove the bearing using the driven pulley shaft or a pin of the same diameter.

N.B.

IF THIS IS DIFFICULT A GENERIC 8 MM EXTRACTOR FOR INNER PARTS CAN BE USED.

REFITTING THE DRIVEN PULLEY SHAFT BEARING

- After slightly heating the crankcase on the inside, fit the bearing using a bush of the same diameter as the bearing outer race.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE.

Page 46

REMOVING THE DRIVEN PULLEY

THE DRIVEN PULLEY

THE CLUTCH DRUM

THE CLUTCH

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the whole of the driven pulley assembly.

N.B.

THE ASSEMBLY CAN ALSO BE REMOVED WITH THE DRIVE PULLEY IN PLACE.

Specific tooling

020565Y Compass flywheel stop spanner

INSPECTING THE CLUTCH DRUM

- To verify that the bell clutch is not usurata or damaged.

- To measure the inner diameter of the bell clutch.

Characteristic

Clutch bell diameter/standard value

0107+0,2 +0 mm

Clutch bell diameter/max, value allowed after use

0 107,5 mm

Found eccentricity /max.

0,20 mm

REMOVING THE CLUTCH

- Fit the tool with the long pins screwed on from the outside in positions «A». Insert the driven pulley assembly into the tool and tighten the central screw.

CAUTION

OVERTIGHTENING OF THE CENTRAL SCREW CAUSES THE DISTORTION OF THE TOOL.

Page 47

- Using a 34 mm socket wrench, remove the clutch locknut.

THE CLUTCH

RETAINING COLLAR

- Loosen the central screw, unloading the spring of the driven pulley assembly.

- Separate the components.

Specific tooling

020444Y Driven half pulley spring compressor tool

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.

N.B.

UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. DIFFERENT CONDITIONS MAY CAUSE THE CLUTCH TEARING.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check. Minimum thickness 1mm

PIN RETAINING COLLAR

- Remove the collar with the aid of two screw drivers.

Page 48

- Remove the three guide pins and the movable half pulley.

THE DRIVEN HALF PULLEY BEARING

THE DRIVEN FIXED HALF PULLEY

REMOVING THE DRIVEN HALF-PULLEY BEARING

- Remove the roller bearing using the specific extractor inserted from the lower side of the stationary half pulley

CAUTION

POSITION THE SEALING EDGE OF THE EXTRACTION PLIERS BETWEEN THE END OF THE BEARING AND THE BUILT-IN SEAL RING.

Specific tooling

001467y029 Bell

- Remove the snap ring from the roller bearing.

- Remove the roller bearing from the side of the clutch using the specific device.

N.B.

ADEQUATELY SUPPORT THE HALF PULLEY TO PREVENT THE DRIVE BELT SLIDING SURFACE FROM BEING DISTORTED.

Specific tooling

020376Y Handle for punches 020363Y 20mm guide

INSPECTING THE DRIVEN FIXED HALF-PULLEY

- Make sure there are no signs of wear on the work surface of the belts, if there are replace the half pulley.

- Make sure the bearing do not show signs of unusual wear.

- Measure the external diameter of the pulley bushing.

Page 49

Characteristic

THE DRIVEN SLIDING HALF PULLEY

Standard diameter

0 33,965 ÷ 33,985 mm

Stationary driven half pulley/ Minimum diameter allowed after use

0 33,96 mm

INSPECTING THE DRIVEN SLIDING HALF-PULLEY

- Remove the two inner seal rings and the two 0-rings.

- Measure the inside diameter of the movable half pulley bushing.

Characteristic

Maximum allowable diameter

0 34,08 mm

- Check the belt contact surfaces.

- Insert the new oil guards and 0-rings on the mobile half pulley.

- Assemble the half pulley on the bushing.

Recommended products

Molybdenum disulphide grease and lithium soap

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Use a.greaser with a curved spout to lubricate the driven pulley unit with around 6 gr. of grease, this operation must be carried out through one of the holes inside the bushing until grease comes out of the opposite hole. This operation is necessary to avoid the presence of grease beyond the 0rings.

Recommended products

Molybdenum disulphide grease and lithium soap

Page 50

REFITTING THE DRIVEN HALF-PULLEY BEARING

G U G

THE CLUTCH SPRING

THE CLUTCH

- Fit a new ball bearing with the specific tools.

- Fit the ball bearing circlip.

- Fit the new roller bearing so that the lettering is visible from the outside.

CAUTION

ADEQUATELY SUPPORT THE HALF PULLEY TO AVOID DAMAGING THE THREADED END WHILE FITTING THE BEARINGS.

Specific tooling

020376Y Handle for punches 020456Y 24 mm adaptor 020362Y 12 mm guide 020171Y Roller bearing drift

INSPECTING THE CLUTCH SPRING

- Make sure that the driven pulley contrast spring is not deformed.

- Minimum length allowed after use

Characteristic

Standard length

118 mm

REFITTING THE CLUTCH

- Preassemble the driven pulley unit with spring, sheathing and clutch.

- Position the spring with the plastic shielding supporting the clutch

- Insert the parts in the device and preload the spring, being careful not to damage the plastic sheathing and the end of the threaded shank.

Page 51

- Reassemble the nut securing the clutch and tighten to the

G U

prescribed torque.

CAUTION

TO AVOID DAMAGING THE CLUTCH NUT, USE A SOCKET WRENCH WITH A SMALL BEVEL.

CAUTION

POSITION THE UNBEVELLED SURFACE OF THE NUT IN CONTACT WITH THE CLUTCH.

Locking torques (N*m)

Nut locking clutch assembly on pulley 55 - 60 Nm

REFITTING THE DRIVEN PULLEY

- Fit the driven pulley assembly, the clutch bell housing and the nut using the specific tool.

Specific tooling

020565Y Compass flywheel stop spanner

Locking torques (N*m)

Driven pulley shaft nut 40 — 44 Nm

DRIVE-BELT

- Make sure the transmission belt is not damaged and does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

transmission bell/Minimum width 17,5mm

Page 52

REMOVING THE DRIVING PULLEY

THE DRIVING PULLEY

GEARS AND BELT

THE ROLLERS CASE

- Lock the pulley with the specific tool.

- Remove the central nut with the related washer, then remove the drive and the plastic fan.

- Remove the fixed half pulley.

- Remove the belt, washer and remove the mobile half pulley with its bushing, being careful of the rollers and contrast plate fitted loosely on it.

Specific tooling

020451y Drive pulley stop spanner

MIXER GEARS AND BELT

- Remove belt and gear

CAUTION

DO NOT TWIST OR BEND THE BELT WHEN REFITTING IT

CAUTION

BEFORE REFITTING THE BELT, CAREFULLY LUBRICATE THE PIN AND THE MIXER DRIVE GEAR BUSHING WITH OIL, MAKING SURE THIS IS FREE FROM ANY LOAD.

N.B.

REPLACE THE BELT EVERY 20,000 KM.

INSPECTING THE ROLLERS CASE

1) Make sure that the bushing and sliding rings on the mobile pulley are not lined or deformed.

2) Check the track where the rollers slide on the contact pulley, there should not be any signs of wear and check the conditions of the belt contact surfaces on the half pulleys (mobile and stationary).

Page 53

3) Make sure that the rollers do not have marked facing on

THE DRIVING PULLEY

the sliding surfaces and that the metal insert does not protrude from the edges of the plastic cover.

4) Make sure that the contact plate sliding blocks are intact.

- Check that the internal bronze bushing shown in the figure is not abnormally worn and measure inside diameter «A».

- Measure outside diameter «B» of the pulley sliding bushing shown in the figure.

CAUTION

DO NOT LUBRICATE OR CLEAN THE BRONZE BUSHING.

Characteristic

Maximum allowable diameter: 20,12 mm

Standard diameter: 20,021 mm

REFITTING THE DRIVING PULLEY

- Manually move the mobile driven pulley by pulling it towards the clutch unit and insert the belt keeping the rotation direction of the first assembly.

N.B.

IT IS ALWAYS A GOOD IDEA TO FIT THE BELT SO THAT THE WORDS ARE LEGIBLE IN CASE THE BELT DOES NOT SHOW AN ASSEMBLY DIRECTION.

- Reassemble the unit parts (roller housing unit with bushing, washer, stationary half pulley, belt cooling fan with intake, washer and nut).

Tighten the nut to a torque of 20 Nm and then finally tighten 90° with the specific tool preventing rotation of the drive pulley.

Page 54

N.B.

SGG O

THE HUB COVER

REPLACE THE NUT WITH A NEW ONE EVERY TIME THE PARTS ARE REASSEMBLED

ATENCIÓN

IT IS VERY IMPORTANT THAT WHEN THE DRIVE PULLEY IS SECURED THAT THE BELT IS FREE INSIDE IT, TO AVOID INCORRECTLY TIGHTENING IT WITH LATER DAMAGE TO THE ENGINE SHAFT MM SCALE.

Specific tooling

020451 y Drive pulley stop spanner

Locking torques (N*m)

Tightening torque plus angle 18÷20 + 90° N.m

DISMANTLING ENGINE PINION

- Loosen: Change output engine pinion bush M16x125.

Specific tool

00G05300131

Tightening torques (N.m)

Change output pinion bush securing device 115 ÷ 125 N.m

REMOVING THE HUB COVER

- Remove the transmission cover.

- Remove the Driven pulley removal

- Discharge the rear hub oil.

- Remove the 5 screws indicated in the figure.

- Remve the hub cover with pulley shaft.

Recommended products

THE TIMING SYSTEM COMPONENTS

Selenia Hi Scooter 2 Tech Oil

Recommended oil

INSPECTING THE TIMING SYSTEM COMPONENTS

CAUTION

CHECK THE LEAK TIGHTNESS OF THE REED VALVE ASSY.; NO LIGHT BE VISIBLE BETWEEN VALVE AND HOUSING.

Page 66

CRANKCASE - CRANKSHAFT

THE CRANKCASE HALVES

THE CRANKSHAFT

THE CRANKSHAFT BEARINGS

PLITTING THE CRANKCASE HALVES

Remove the eight crankcase fasteners.

Install the special plate on the flywheel-side half crankcase and proceed by splitting the two halves.

Specific tooling

020163y Crankcase splitting plate

REMOVING THE CRANKSHAFT

- Install the special tool onto the transmission-side halfcrankcase using four M6 screws of adequate length.

- Remove the crankshaft from the transmission side halfcrankcase.

Specific tooling

020163y Crankcase splitting plate

REMOVING THE CRANKSHAFT BEARINGS

The bearings may remain attached either to half- crankcase or crankshaft, indifferently.

- Using the special tool provided, remove only the bearings attached to the engine.

N.B.

THE HALF RINGS MUST BE FITTED ONTO THE BEARINGS WITH THE AID OF A MALLET.

Page 67

Specific tooling

THE CRANKSHAFT BEARINGS

004499y001 Bearing extractor fitted with parts

004499y006 Bearing extractor fitted with parts

004499y002 Bearing extractor fitted with parts

004499y007 Half rings

Using the special tool, remove any bearing which remained on the crankcase.

Specific tooling

001467Y007 Bell for bearings external 0 54 mm

001467Y006 20-mm pliers

REFITTING THE CRANKSHAFT BEARINGS

Heat the bearings in oil at approx. 100°C and fit them onto the crankshaft with the aid, if necessary of tube section acting directly on the internal ring of the bearing.

Specific tooling

020265y Bearing fitting stand

Page 68

INSPECTING THE CRANKSHAFT ALIGNMENT

THE CRANKSHAFT ALIGNMENT

G CS

Using the appropriate specific tools, check the eccentricities of the surfaces of diameters «A»-«B»-« C» are within 0.03 mm (top reading limit for the dial gauge clock); check also the eccentricity of diameter «D», for which a maximum misalignment of 0.02 mm is allowed. In the event that the eccentricities are not too far off the prescribed values, straighten the crankshaft by acting with a wedge in between the counterweights or by using vice (with aluminium mouth guards) according to your needs.

Specific tooling

020335Y Magnetic stand and comparator

020074Y Crankshaft aligning tool

REFITTING THE CRANKSHAFT

- Rest the transmission-side half-crankcase on two wooden supports.

- Using a heat gun, heat the bearing housing up to approx. 120 °.

- Insert the crankshaft and push it in as far as the bearing will go.

Page 69

- Let the half-crankcase temperature settle with that of the

THE CRANKCASE HALVES

crankshaft.

- Reinstall the crankcase splitting plate WITHOUT installing the crankshaft protection.

- During the reassembly process keep the centre thrust screw loose.

- Tighten the four fixing screws and then loosen them with the same angle (e.g. 90°)

- When the temperature has settled manually preload the tool’s thrusting screw until the ball bearing play disappears.

Specific tooling

020163y Crankcase splitting plate

REFITTING THE CRANKCASE HALVES

- Prepare the mating plane by applying a thin layer of LOCTITE 510, after cleaning the surface with and adequate solvent (e.g. acetylene trichloride).

- Heat the flywheel-side half-crankcase using a heat gun.

Recommended products

Loct’rte 510 Packing fluid Packing

- Keeping the transmission-side half-crankcase in horizontal position, vigorously and accurately insert the flywheel-side half-crankcase.

- Insert at least 3 fixing screws and tighten them quickly.

- Insert the other 5 screws and tighten them at the prescribed torque.

Locking torques (N*m)

Crankcase fixing screws 11-13

Page 70

- Move the crankcase splitting plate backwards as shown in the figure.

- Install the special magnetic mounting with its dial gauge, at the end of the crankshaft.

- Check the crankshaft axial play.

- If the measurements do not match those prescribed, repeat the crankshaft reassembly operation.

Specific tooling

020335Y Magnetic stand and comparator

Characteristic

Axial play with warm crankcase

0,10 ÷ 0,12 mm

Axial play with cold crankcase

0,06 ÷ 0,08 mm

Limit value with cold crankcase

0,02 ÷ 0,03 mm

LUBRICATION CRANKSHAFT OIL SEALS

Refitting

- Install a new flywheel-side oil seal using the puncher from the special tool.

- The flywheel-side oil seal may be recognised for having a smaller diameter.

N.B.

THE SPECIAL TOOL MAY NOT BE USED WHEN THE WOODRUFF KEY IS FITTED

Specific tooling

020340Y Punch for fitting oil guard magneto and transmission

Page 71

- Install a new transmission-side oil seal using the special tool fitted with adapter ring.

- The transmission-side oil seal may be recognised by its larger diameter.

Specific tooling

020340Y Punch for fitting oil guard magneto and transmission

OIL PUMP

EMOVAL

Remove the two screws shown in the figure.

Remove the fairlead from the crankcase, as indicated in the figure.

REFITTING

- For the reassembly follow the removal operations in the reverse order.

- After the reassembly, it is recommended to bleed the system by acting upon the screw shown in the picture.

Page 72

FUEL SUPPLY

SUPPLY

The vehicle is fitted with a membrane pump controlled via the vacuum generated in the intake duct. The tank is therefore fitted with a hole located at its lowest point, which allows fuel to flow to the pump and then to the carburettor.

To check the pump performance, the following mass flow measurement may be carried out:

1) Start the engine, warm it up to the standard operating temperature, and shut it down.

2) Detach the fuel inlet tube on the carburettor and insert it inside a scaled recipient.

3) Start the engine without twisting the throttle, and let it run at idle.

4) Let the engine run for a total of 10 seconds, from start-up and shut it down.

5) Check the quantity of fuel is not less than prescribed.

Characteristic

Fuel supplied

~100ccX10 ”

Page 73

SEBAC FORKS

Forks assembly

1 2

Stem-plate subassembly Fork stem securing washer

3 4

Fork arm securing safety ring

10M150x50 hexagonal bolt

8M125x35 ZnB Allen bolt

Arm securing bolt washer

Fork arm plug

Fork pipe plug ring

Fork spring

Hydraulic piston spring

Hydraulic piston ring

Fork arm retainer washer

Fork arm pipe Hydraulic pipe

15 16

Fork arm guide bush

Arm bush washer

Fork arm retainer

Fork arm ring

Fork dust guard Right hand end point

Left hand end point

D10 Int. star washer

8M125x30 Allen bolt

Stem securing nut

Page 74

MARZOCCHI FORKS

OCC OS

8M125x30 Allen bolt

1 2

Right hand end point hydraulic assembly Fork arm securing ring

Fork arm guide bush

Arm guide bush washer

Fork arm retainer

Oil seal ring

7 8

Fork arm dust guard Fork arm assembly

8M125x30 Allen bolt

Arm securing bolt washer

Fork plug ring

Fork plug assembly

13 14

10M150x50 Hexagonal bolt Plate stem assembly

Left hand end point hydraulic assembly

16 17

Stem securing nut Forks assembly

Page 75

DISMANTLING FRONT SUSPENSION

FRONT SUSPENSION

ATTENTION

TO CARRY OUT THE PROCESS OF DISMANTLING THE FORKS WITHOUT REMOVING THEM FROM THE BOTTOM PLATE. TO DO SO, HOLD THE FORKS IN A BENCH VICE BY THE STEERING COLUMN, THEREBY PREVENTING THEM FROM BEING SCRATCHED.

- Extract the top closing bolt.

- Remove the top bolt.

ATENCIÓN

THE BOTTOM BAR OF THE FORKS WILL COME FREE. HOLD IT TO PREVENT IT FROM FALLING.

Have ready a suitable sized container in which to drain off the hydraulic fluid from each bar (pump the fork stem assembly in order to ensure it is completely drained).

Page 76

Extract the spring and the preload spacer.

- Extract the oil seal dust guard together with its security circlip.

- Firmly separate the bar from the fork stem.

Extract the elements:

- Dust guard (1).

- Oil seal (2).

- Washer (3).

- Scraper (4).

Page 77

- Proceed with cleaning and degreasing all the front sus-

THE FRONT FORKS

pension components, so that they can be subsequently checked.

INSPECTING THE FRONT FORKS

- Check the degree of wear on the suspension bar guide bush. Replace it in the event of it being damaged on over 30% of its total surface.

- With the aid of some X-shaped chocks and a comparison meter fitted on a fixed support, determine the degree of non-alignment of the bar.

Service limit: 0,4 mm.

- Check the length of the suspension spring, as well as its distortion and/or lack of parallelism.

- Check the state of the rebound spring and the airtight Oring. Replace them in the event of evident distortion or damage.

Clean and degrease all the elements making up the assembly, ready for reassembly.

Page 78

Reassemble the assembly, paying special attention to the tightening of the fork stem, as well as the fitting of the oil seal, putting a little oil on its edges and inserting it with the aid of the special tool. Refill the hydraulic fluid and do not forget to insert the preload bush between the spring and the closing plug.

SUSPENSION

FREE LENGTH OF SPRING (MM)

cm3 OIL / BAR

TYPE OF OIL

SEBAC / MARZOCCHI 193.8 145 ± 2 SAE 7,5 W

Fork elements tightening torques:

- Guide fork to the chassis

90 ÷ 130 N.m (9 ÷ 13 m.kg)

- Fork stem closing

15 ÷ 19 N.m (1.5 ÷ 1.9 m.kg)

1. Refit all the components:

- Readjust forks to the chassis.

- Refit the front fairing.

- Connect the headlight cables, the turn indicators and the dashboard.

NOTA

TIGHTEN ALL BOLTS TO THEIR NOMINAL TORQUE.

- Top forks to the chassis: 90 ÷ 130 N.m (9 ÷ 13 kg.m)

2. Dismantle:

Front fairing

- Disconnect lighting connections.

- Disconnect dashboard connections.

4. Separate:

Forks wheel assembly (downwards).

5. Check:

- Functioning (top and bottom bearings). Push the handlebars down several times.

Irregular functioning => Repair.

See “FRONT FORKS” in CHAPTER 6.

Page 79

Swinging arm assembly

14M 20 0 ZnB Hexagonal nut

Shock absorber assembly

10M150x60 ZnB Allen bolt

D10D125 ZnB Washer 10M150 ZnB Hexagonal nut

10M150x60 ZnB Allen bolt

8 9

Shock absorber bottom separator bush Swinging arm outer stop bush

Swinging arm shaft bush

Chain cover Bolt 4.8 x 13

13 14

Flat washer Chain rubbing plate

Aluminium plate

Page 80

DISMANTLING

1. Place the motorcycle on a flat surface.

WARNING

ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING.

2. Extract:

- Rear wheel.

- Wheel sprocket.

- Brake disk.

- Rear calliper.

3. Extract:

- Nut (top and bottom).

- Shock absorber.

4. Extract:

- Swinging arm shaft nut.

- Wheel axle nut.

- Washers (swinging arm).

- Shafts.

- Swnging arm.

INSPECCIÓN

1. Inspect:

- Swinging arm play Play => Tighten the joint shaft nut or replace the bushes.

- Swinging arm vertical movement Irregular movement/warping/stains => Replace the bushes.

2. Inspect:

- Shock absorber Fluid leaks/damage => Replace the shock absorber.

Page 81

FRONT WHEEL DIAGRAM

O G

Front wheel rim

120/70-14in front tyre

Wheel air valve assembly

M14x150 wheel axle nut protector

Wheel separator bush

C/ALL 10M 150x60 D912 8ZnB bolt

DIN 125-A-ST front wheel axle.

7 8

D15 DIN 125-A-ST flat washer D-934 wheel axle head nut

D.245 front brake disk

FR.(6x20) Zn.B10.9 disk securing bolt

Bearing

R- Bearing separator assembly

R-brake calliper assembly

R-brake pad assembly

R-Pad securing spring

R-Front brake calliper bleeding assembly

Page 82

DISMANTLING

THE FRONT WHEEL

WARNING

- ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING.

- PLACE THE MOTORCYCLE ON A FLAT SURFACE.

1. Extract:

- Front brake calliper (Bolts 1 and 2).

2. Extract:

- Nut protecting cover.

- Nut (left side).

3. Raise:

- Front wheel (Put a suitable support under the engine).

4. Extract:

- Front wheel axle.

- Front brake disk assembly.

- Dustguard/spacer.

- Front wheel.

INSPECTING THE FRONT WHEEL

1. Inspect:

- Front wheel axle. (By rolling it on a flat surface).

Warping => Replace.

WARNING

DO NOT TRY STRAIGHTENING A WARPED AXLE.

Wheel axle warp limit:

0,25 mm

2. Inspect:

- Neumático delantero.

Damage/wear => Replace.

Page 83

3. Check:

- Spokes.

Warps/damage => Replace.

4. Measure:

- Distortion of the front wheel

Above that specified => Replace.

Distortion limits for the front wheel: Radial (a):

0,5 mm

Lateral (b):

0,8 mm

5. Check:

- Front wheel bearings.

Bearings allow play in the wheel hub or the wheel does not turn freely => Replace.

- Retaining rings.

Damage/wear => Replace.

6. Inspect:

- Spacer.

With scratches/worn => Replace the spacer and the

retaining ring.

Page 84

DISMANTLING THE FRONT DISK CALLIPER

THE FRONT DISK CALLIPER

- Loosen the banjo bolt (1) from the bottom end of the brake pipe and tighten it slightly.

- Unscrew the calliper mounting bolts (2) and separate the calliper (3) backwards from the disk.

PRECAUTION

CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY.

Fitting the front calliper:

- Fit the bottom end of the brake pipe and the calliper.

- Tighten to nominal torque.

- Tighten the brake banjo bolt.

- Check brake fluid level.

- Bleed the brake system pipe (consult “Bleeding the brake system pipe” in this chapter).

- Check the condition of the braking force to see if any resistance is noted or any loss of fluid.

WARNING

DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER IS OPERATING PROPERLY. PUMP THE LEVER UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKES WILL NOT WORK THE FIRST TIME THE LEVER IS USED.

Page 85

Extracting the front brake pads.

- Remove the front brake calliper (see “Dismantling the front brake calliper” in this chapter).

Extract:

- Pad springs (1).

- Pin.

- Brake pads (2).

Fitting the front brake pads

- Press the calliper pistons in manually.

- Fit the pads inside the calliper.

- Adjust the pad springs.

WARNING

DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER IS OPERATING FULLY. THIS IS ACHIEVED BY PUMPING THE LEVER UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKES WILL NOT WORK THE FIRST TIME THE LEVER IS USED.

Inspecting the pads for wear

- Remove the front brake pads.

- Examine both brake pads. If the wear has caused the wear indicating groove (1) to disappear, both pads must be renewed.

Extracting the front brake cylinder.

- Extract the bolt (1) and remove the flexible pipe from the brake cylinder reservoir.

Page 86

N.B.

THE MASTER CYLINDER (1) IS INCORPORATED INTO THE FRONT BRAKE LEVER ASSEMBLY.

- EXTRACT THE SCREWS (2) AND THE FRONT BRAKE LEVER ASSEMBLY.

PRECAUTION

CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY.

Extract:

- Brake lever mounting bolt and nut.

- Brake lever.

Fitting the front master cylinder:

- Fit the brake lever assembly and tighten the securing screw.

- Tighten the flexible brake pipe bolt.

- Bleed the brake system pipe (consult “Bleeding the brake system pipe” in this chapter).

- Check the condition of the braking force to see if any resistance is noted or any loss of fluid. Checking the brake lever master cylinder (visual check):

- Extract the master cylinder (consult “Extracting the front master cylinder” in this section).

- Dismantle the front master cylinder:

- Check that there are no scratches, corrosion or holes on the inner walls of the master cylinders and on the outer part of each piston.

- If any damage is discovered on the master cylinder or on the pistons, change them.

- Examine the primary seal and secondary seal.

- If the seal is worn, soft (perished) or swollen, change the piston assembly to renew the seals.

- If fluid loss is noticed at the brake lever, change the seals.

Page 87

Checking the brake calliper main cylinder:

- Check that the anti-dust boots are not damaged. If they are, change them.

- Check that the piston return is not damaged. If it is, renew it.

- Check that the relief port and feed port are not blocked. if the relief port is blocked, the brake pads will bind on the disk. Inject compressed air to clean the ports.

Extracting the brake disk:

- Remove the front wheel.

- Unscrew the mounting bolts and extract the disk.

Fitting the brake disk

- Fit the brake disk onto the front wheel so that side (2) faces outwards.

- Apply a temporary blocking device to the threads of the brake disk mounting bolts(1).

- Tighten the front brake disk mounting bolts(1).

Nominal tightening torque:

0.8 ÷ 1 m.kg (8 ÷ 10 N.m)

Wear to the brake disk:

- Measure the thickness of the disks (A) at the point where they are most worn.

- If the disk is more worn than specified in the service limit, renew it.

Measurement area (B).

Standard thickness of the front brake disk.

3.3 ÷ 3.6 mm.

Service limit:

3.1 mm

Page 88

Brake disk distortion:

- Raise the motorcycle on the jack so that the tyre is clear of the ground.

- To check the front disk, turn the handlebars completely to one side.

- Place a dial calibrator against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is turned by hand (B).

- If the deviation from centre exceeds the service limit, renew the disk.

Disk deviation from centre:

Standard:

less than 0.15mm

Service limit:

0,3 mm

Bleeding the brake system pipe

The brake fluid has a very low compression coefficient, with the result that almost all the movements of the brake lever are transmitted directly to the calliper for braking. Air however compresses easily. When air enters the brake system pipes, the movement of the brake lever is partially used up in compressing the air. This causes the lever to feel spongy and leads to a loss of braking power.

WARNING

BE SURE TO BLEED AIR OUT OF THE BRAKE SYSTEM WHEN THE BRAKE LEVER FEELS SPONGY AFTER CHANGING THE BRAKE FLUID OR WHEN THE BRAKE SYSTEM PIPE HAS BEEN LOOSENED FOR ANY REASON.

Extract:

- Bolts (1).

- Reservoir cap (2).

- Fill the reservoir with brake fluid up to the top reservoir line.

- With the cap removed, pump the brake lever slowly several times until no bubbles can be seen rising through the liquid.

Page 89

Purge the air completely from the master cylinder using this procedure.

- Remove the transparent plastic cap from the bleed nipple and place the other end of the pipe in a container.

- Repeat the following procedure until there is no air left emerging from the plastic pipe:

- Pump the brake lever until it becomes hard and holds the brakes down.

- Open and close the purge valve quickly while keeping the brake on.

- Release the brake.

N.B.

CHECK THE FLUID LEVEL FREQUENTLY DURING THE BLEEDIING OPERATION AND REPLENISH THE RESERVOIR WITH BRAKE FLUID WHEN NECESSARY. IF THE RESERVOIR EMPTIES COMPLETELY OF BRAKE FLUID AT ANY TIME THE DURING BLEEDING PROCEDURE, PERFORM THE BLEEDING PROCEDURE ALL OVER AGAIN FROM THE BEGINNING, SINCE AIR WILL HAVE ENTERED THE PIPE. TAP THE BRAKE PIPE LIGHTLY FROM THE CALLIPER TO THE RESERVOIR TO ACHIEVE A MORE COMPLETE BLEEDING.

- Extract the transparent plastic pipe.

Fit:

- Reservoir cap.

- Cap securing screws.

-Tighten the bleed valve and fit the rubber hood.

- Check brake fluid level.

- Once the bleeding process has been carried out, check the efficiency of the brake to see if there is any resistance or any fluid loss.

WARNING

WHEN WORKING WITH THE DISK BRAKE, TAKE THE FOLLOWING PRECAUTIONS:

1) NEVER RE-USE BRAKE FLUID.

2) DO NOT USE FLUID FROM A CONTAINER THAT HAS BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PROLONGED PERIOD OF TIME.

Page 90

3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR

ASSEMBLING

THE FRONT WHEEL

USE IN THE BRAKE. THIS LOWERS THE BRAKE FLUID EVAPORATION POINT AND MAY RESULT IN THE BRAKES NOT WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DETERIORATION OF THE BRAKE PARTS.

4) DO NOT LEAVE THE RESERVOIR CAP OFF AT ANY TIME, TO PREVENT CONTAMINATION OF THE FLUID.

5) DO NOT CHANGE THE FLUID IN RAINY OR VERY WINDY CONDITIONS.

6) EXCEPT ON THE BRAKE LININGS AND THE DISK, USE ONLY BRAKE FLUID, ISOPROPILIC ALCOHOL OR ETHYL ALCOHOL FOR CLEANING BRAKE PARTS. DO NOT USE ANY OTHER TYPE OF LIQUID FOR CLEANING THESE PARTS.

PETROL, ENGINE OIL OR ANY OTHER PETROLEUM DISTILLATE WILL CAUSE RUBBER PARTS TO DETERIORATE. IF OIL IS SPILT ON ANY PART, IT WILL BE DIFFICULT TO CLEAN COMPLETELY AND MAY DETERIORATE THE RUBBER USED IN THE DISK BRAKE.

7) ON HANDLING THE DISK BRAKE LININGS OR THE DISK, TAKE CARE TO ENSURE THAT NO BRAKE FLUID COMES INTO CONTACT WITH THEM. CLEAN ANY REMAINS OF BRAKE FLUID THAT ACCIDENTALLY COMES INTO CONTACT WITH THE LININGS OR WITH THE DISK WITH A SOLVENT WITH A HIGH INFLAMMATION POINT. DO NOT USE ONE THAT LEAVES GREASY RESIDUES. IF LININGS CANNOT BE CLEANED SATISFACTORILY, CHANGE THEM FOR NEW ONES.

8) BRAKE FLUID DESTROYS PAINTED SURFACES RAPIDLY. CLEAN OFF ANY SPILT REMAINS IMMEDIATELY.

9) IF ANY OF THE BRAKE SYSTEM PIPE SECURING SYSTEMS OR THE BLEED VALVE OPENS AT ANY TIME, THE AIR CAN BE BLED FROM THE BRAKE SYSTEM PIPE.

ASSEMBLING THE FRONT WHEEL

1. Fit:

- Speedometer assembly

Page 91

ASSEMBLING THE FRONT WHEEL

THE FRONT WHEEL

Reverse the “DISMANTLING” procedures. Take care

with the following points:

1. Lubricate:

- Front wheel axle.

- Bearing.

- Retaining rings.

Recommended lubricant:

Lithium soap based grease

2. Fit:

- Front wheel

3. Tighten:

- Front wheel axle.

- Axle nut (front wheel).

ATTENTION

BEFORE TIGHTENING THE WHEEL AXLE, PUSH THE FRONT FORKS DOWN SEVERAL TIMES, HOLDING THE HANDLEBARS, TO CHECK THEIR OPERATION.

Axle nut:

70-80 N.m (7-8 kgf.m)

WARNING

ENSURE THAT THE SPEEDOMETER CABLE GUIDE IS CORRECT.

4. Check:

Front brake functioning Irregular functioning => Dismantle or check again.

- Brake lever play

Page 92

WHEEL DIAGRAM

GP1 front wheel

120/70-14in rear tyre

Air valve assembly

Rear wheel axle assembly

14M 20 0 ZnB nuts

GP1 drag plate

(6x20) Zn.B10.9 brake disk securing bolt

D.180 rear brake disk

ZnB rear brake disk securing bolt

GP1 secondary chain

Secondary chain coupling

Bearing

Bearing separator

Connector Washer

15 16

Wheel tensioner

Wheel tensioner cap

6M100x60 chain tensioner bolt

Aut.6M100 DIN-985.8 ZnB nut

Plate side bush

GP1 rear calliper assembly

Rear brake liquid cable

Rear brake cable securing clamp

c/Red Cross 5M8Ox16D7985NG bolt

Brake pad securing spring

25 26

Rear brake calliper bleed nipple 5M80 DIN-982 self-locking nut

D5 ZnB flat washer

Rear brake puller

Main connecting rod securing bolt

Washer

31 32

10M150 DIN985 ZnB nut

Brake pad set

Page 93

DISMANTLING

THE REAR DISK CALLIPER

WARNING

- ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING.

- PLACE THE MOTORCYCLE ON A FLAT SURFACE.

1. Extract:

- Wheel axle (1).

- Spacer.

N.B.

ON WITHDRAWING THE WHEEL AXLE, THE SPACER WILL DROP DOWN. TAKE CARE NOT TO LOSE IT.

2. Extract:

- Rear wheel.

N.B.

ON EXTRACTING THE WHEEL, PUSH THE WHEEL FORWARDS TO REMOVE THE DRIVE CHAIN, THEN EXTRACT THE WHEEL BACKWARDS TO AVOID THE BRAKE CALLIPER.

DISMANTLING THE REAR DISK CALLIPER

- Loosen the bolt at the bottom end of the flexible brake hose and tighten it slightly (1)

- Unscrew the bolt securing the brake puller (2) and remove the clips (3) joining the flexible hose to the puller.

- Extract the wheel axle (4).

- Remove the brake calliper (5).

PRECAUTION

CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY.

Page 94

Fitting the rear calliper

- Fit the bottom end of the flexible brake pipe and the calliper.

Fit the wheel axle, the brake puller and the flexible hose securing clips.

Nominal torque (wheel axle):

110 -130 N .m (11-13 kgf. m )

Tighten to nominal torque (brake puller): 35-40 N.m (3,5 – 4 kgf.m)

- Tighten the brake banjo bolt.

- Check brake fluid level.

- Bleed the braking system pipe (consult “Bleeding the brake system pipe”, in the chapter corresponding to the front brakes).

- Check the condition of the braking force to see if any resistance is noted or any loss of fluid.

WARNING

Extracting the rear brake pads

- Remove the rear brake calliper (see “Dismantling the rear brake calliper”, in this chapter).

Extract:

- Pad springs (1).

- Brake pads.

Fitting the rear brake pads.

- Press the calliper pistons in manually.

- Fit the pads inside the calliper.

- Adjust the pad springs.

Page 95

WARNING

DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE PEDAL IS OPERATING FULLY. PUMP THE LEVER UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKE WILL NOT WORK THE FIRST TIME THE PEDAL IS USED.

Inspecting the pads for wear

- Removing the rear brake pads.

- Examine both brake pads.

If the wear has caused the wear indicating groove (1) to disappear, both pads must be renewed.

Extracting the rear main cylinder

- Remove the cover protecting the main cylinder. (The bolts securing the cover also support the cylinder)

- Extract the bolt and remove the flexible hose from the brake cylinder reservoir.

PRECAUTION

CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY.

Fitting the rear main cylinder.

- Fit the rear main cylinder and its protective cover.

- Tighten the brake flexible hose bolt.

- Bleed the brake system pipe (consult “Bleeding the brake system pipe” in this chapter).

- Check the condition of the braking force to see if any resistance is noted or any loss of fluid.

Page 96

Checking the rear main cylinder (visual check)

- Extract the main cylinder (consult “Extracting the rear main cylinder” in this section).

- Dismantle the rear main cylinder.

- Check that there are no scratches, corrosion or holes in the inner walls of the main cylinder and on the outer part of each piston.

If any damage is discovered on the master cylinder or on the pistons, change them.

- Examine the primary and secondary seals.

- If a seal is worn, soft (perished) or swollen, change the piston assembly to renew the seals.

- If you notice loss of fluid in the brake cylinder, change the seals.

Checking the rear calliper main cylinder

- Check that the anti-dust boots are not damaged. If they are, change them.

- Check that the piston return is not damaged. If it is, renew it

- Check that the relief port and feed port are not blocked. if the relief port is blocked, the brake pads will bind on the disk. Inject compressed air to clean the ports.

Extracting the brake disk

- Extract the rear wheel.

- Unscrew the mounting bolts and extract the disk.

Fitting the brake disk

- Fit the brake disk to the rear wheel in such a way that the engraved side faces outwards.

- Apply a temporary blocking device to the threads of the brake disk mounting bolts.

- Tighten the rear brake disk securing bolts.

Nominal tightening torque:

2.5 ÷ 2.9 m-kg (25 ÷ 29 N.m)

Page 97

Brake disk wear

- Measure the thickness of the disks (A) at the point where they are most worn.

- If the disk is more worn than specified in the service limit, renew it.

Measurement area (B).

Standard brake disk thickness:

3.3 ÷ 3.6 mm.

Service limit:

3.1 mm.

Brake disk distortion

- Raise the motorcycle on the jack so that the tyre is clear of the ground.

- Place a dial calibrator against the disk (A) as shown, and measure the disk’s deviation from centre as the tyre is turned (B) by hand.

- If the deviation from centre exceeds the service limit, renew the disk.

Disk deviation from centre:

Standard:

Inferior a 0,15 mm

Service limit:

0,3 mm

Bleeding the brake system pipe

The brake fluid has a very low compression coefficient, with the result that almost all the movements of the brake lever are transmitted directly to the calliper for braking. Air however compresses easily. When air enters the brake system pipes, the movement of the brake lever is partially used up in compressing the air. This causes the pedal to feel spongy and leads to a loss of braking power.

WARNING

BE SURE TO BLEED AIR OUT OF THE BRAKE SYSTEM WHEN THE BRAKE LEVER FEELS SPONGY AFTER CHANGING THE BRAKE FLUID OR WHEN THE BRAKE SYSTEM PIPE HAS BEEN LOOSENED FOR ANY REASON.

Remove:

Reservoir cap (threaded)

- Fill the reservoir with new brake fluid up to the top reservoir line.

- With the cap removed, pump the brake slowly several times until no more bubbles rise up through the fluid.

Page 98

Extract:

- Bolts (1).

- Reservoir cap (2).

- Fill the reservoir with brake fluid up to the top reservoir line.

- With the cap removed, pump the brake lever slowly several times until no bubbles can be seen rising through the liquid.

Purge the air completely from the master cylinder using this procedure.

- Remove the transparent plastic cap from the bleed nipple and place the other end of the pipe in a container.

- Repeat the following procedure until there is no air left emerging from the plastic pipe:

- Pump the brake lever until it becomes hard and holds the brakes down.

- Open and close the purge valve quickly while keeping the brake on.

- Release the brake.

NOTA

- Extract the transparent plastic pipe.

Fit:

- Reservoir cap.

- Cap securing screws.

-Tighten the bleed valve and fit the rubber hood.

- Check brake fluid level.

- Once the bleeding process has been carried out, check the efficiency of the brake to see if there is any resistance or any fluid loss.

Page 99

WARNING

WHEN WORKING WITH THE DISK BRAKE, TAKE THE FOLLOWING PRECAUTIONS:

1) NEVER RE-USE BRAKE FLUID.

2) DO NOT USE FLUID FROM A CONTAINER THAT HAS BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PROLONGED PERIOD OF TIME.

3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR USE IN THE BRAKE. THIS REDUCES THE BRAKE FLUID EVAPORATING POINT AND MAY RESULT IN THE BRAKES NOT WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DETERIORATION OF THE BRAKE PARTS.

4) DO NOT LEAVE THE RESERVOIR CAP OFF AT ANY TIME, TO PREVENT CONTAMINATION OF THE FLUID.

5) DO NOT CHANGE THE FLUID IN RAINY OR VERY WINDY CONDITIONS.

6) EXCEPT ON THE BRAKE LININGS AND THE DISK, USE ONLY BRAKE FLUID, ISOPROPILIC ALCOHOL OR ETHYL ALCOHOL FOR CLEANING BRAKE PARTS. DO NOT USE ANY OTHER TYPE OF LIQUID FOR CLEANING THESE PARTS. PETROL, ENGINE OIL OR ANY OTHER PETROLEUM DISTILLATE WILL CAUSE RUBBER PARTS TO DETERIORATE. IF OIL IS SPILT ON ANY PART, IT WILL BE DIFFICULT TO CLEAN COMPLETELY AND MAY DETERIORATE THE RUBBER USED IN THE DISK BRAKE.

8) BRAKE FLUID DESTROYS PAINTED SURFACES RAPIDLY. CLEAN OFF ANY SPILT REMAINS IMMEDIATELY.

9) IF ANY OF THE BRAKE SYSTEM PIPE SECURING SYSTEMS OR THE BLEED VALVE OPENS AT ANY TIME, THE AIR CAN BE BLED FROM THE BRAKE SYSTEM PIPE.

Page 100

INSPECTING THE REAR WHEEL

THE REAR WHEEL

1. Inspect:

- Rear wheel axle

- Rear wheel

- Rear wheel bearings

- Retaining rings

See the “WHEEL AND REAR BRAKE” section

2. Measure:

- Distortion of the rear wheel

See the “WHEEL AND REAR BRAKE” section

FITTING THE REAR WHEEL

Reverse the “DISMANTLING” procedures.

Take care with the following points:

1. Fit:

- Rear wheel.

2. Adjust:

- Drive chain tension

Transmision chain

- Check the drive chain tension. When pressed with a finger, there should be a play of 12÷18mm. If adjustment is needed, proceed as follows: loosen the wheel nut and adjust the tensor by turning thern dockwise, giving the same number of turns of the right and left tensor. In this way the wheel will be correctly aligend. Thighten the wheel nut.

- Due to the geometrical features of the vehicle the tightness of the chain must be checked regularly with the rider sitting on the vehicle always.

3. Tighten:

- Rear wheel axle.

- Axle nut (rear wheel) (1).

Nut (rear wheel axle):

70 ÷ 80 N.m (7 ÷ 8 m.kg)

4. Check:

- Brake pedal play

Derbi GP1 50 cc Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual