derbi predator LC shop SH Workshop Manual

This manual has been prepared by DERBI Nacional Motor, S.A.

Sociedad

Unipersonal

for use by concessionaires and DERBI sub-agency workshops. It is assumed that persons using this work for the maintenance and repair of DERBI vehicles will have a basic grounding in the principles of mechanics and the necessary technical methods used in the repair of such vehicles. Major variations in the technical specifications of the vehicles or in specific repair operations will be communicated by means of updates to this manual.

Nevertheless, completely satisfactory work cannot be performed without the necessary installations and tools: for this reason we strongly recommend that you consult the pages in this manual which refer to specific tools and equipment.

Information in this manual which is of particular importance is indicated by the following notes:

N.B.

This indicates a note which gives key information for performing the

procedure more easily and clearly.

This indicates specific procedures which should be followed to

avoid causing damage to the vehicle.

This indicates procedures which should be followed to avoid

possible injury to the person carrying out the repairs to the vehicle.

Caution!

Warning !!!

All data may be changed without prior notice.

Derbi declines all responsibility for the use of non-original parts and accessories

which have not been tested and approved.

 DERBI - NACIONAL MOTOR Sociedad Unipersonal / 2002 • Dep. Leg. GI-1302-2000 • N.º 80881158407

fourth edition - May 2002

INDEX

Predator-LC / O2 Atlantis-LC / O2 / 100 Models

Hunter - Paddock - Vamos Models

Technical specifications of the engine _4 Special tools_____________________5 Regular maintenance table _________6 Torque settings___________________7 Front forks - HUNTER _____________8 Front forks - PADDOCK____________9 Front forks - VAMOS ______________9 Withdrawing the engine

from the frame ________________10 Stripping the engine ______________11 Assembly of the engine ___________16 Crankshaft inspection_____________18 Assembly of right hand crankcase

bearing ______________________19 Water pump ____________________20

Assembly of sliding weight hub _____22 Clutch assembly_________________23 Reduction gear__________________24 Left hand crankcase cover_________24 Cylinder head, cylinder,

and piston____________________27 Carburettor_____________________30 Cylinder sleeve cover,

radiator and filter box ___________33 Fitting the engine in the frame ______35 Electrical system ________________36 Electrical wiring diagrams _________45

Regular Maintenance Table________50 Torque settings__________________51 Front forks _____________________52 Rear suspension ________________54 Removing the engine

from the frame ________________56

Magneto_______________________57 Cylinder head, cylinder and piston___58 Crankshaft - Variable speed unit ____60 Carburettor_____________________61 Electrical system ________________62 Electrical wiring diagrams _________65

Engine Piaggio Models

Special tools_________________________74 Regular Maintenance Table__________77 Torque settings ______________________78 Paioli front forks _____________________79 Engine ______________________________80 Magneto_____________________________81 Electronic ignition____________________83 Transmission - mixer_________________84 Cylinder head - cylinder - piston

(Liquid cooled models) ____________95

Crankcase halves - crankshaft _______98 Secondary air system_______________102 Cylinder head - cylinder - piston

(Air cooled models) ______________104 Vehicle service data ________________107 Carburettors ________________________110 Electrical system____________________111 Electrical wiring diagrams___________113

Engine

Number of cylinders.................1

Cycle........................................2-stroke

Stroke and Bore.......................41 x 37.4 mm

Cubic capacity..........................49cc

Fuel admission.........................reed valve direct to crankcase

Compression ratio....................11.5 : 1

Starter system..........................electric start

Engine cooling system.............fan-driven pressurised air

LC: liquid cooling

Fuel..........................................Unleaded fuel

Lubrication system...................petrol-oil mixture, using constant flow pump driven lubrication

Atlantis 100:

Stroke and Bore.......................50 x 43 mm

Cubic capacity..........................85cc

Compression ratio....................9.5 : 1

Carburettor

Type.........................................

DELL’ORTO PHVA 10.GD / PHVA12 DD / PHVA 14 DD / PHVA 17.5

WEBER 14 OM 1 AA / WEBER 14 OM 1 BA / WEBER 12 OM 1 QA

WEBER 12 OM 1 SA / WEBER 14 OM 1 FA

Primary drive...............................automatic variable speed unit through trapezoidal belt drive

Clutch ..........................................automatic centrifugal dry clutch

Ignition

System.....................................magneto 12V 80W.

Ignition advance.......................18º before T.D.C.

Spark plug................................NGK B8 HS / CHAMPION L.78 C.

NGK B9 ES / CHAMPION N.2.C / NGK B8 ES / CHAMPION N3C

Battery......................................12V 4Ah

TECHNICAL SPECIFICATIONS OF THE ENGINE

Part Name Reference Number

1.- Magneto disassembly tool unit..............................................................0.0G.053.0.001.1

2.- Connecting rod blocking tool.................................................................0.0G.056.0.037.1

3.- Water pump shaft extractor tool............................................................0.0G.056.0.042.1

4.- Crankshaft assembly tool (use for water pump shaft)...........................0.0G.056.0.036.1

5.- Crankshaft seal guide bush...................................................................0.0F .053.0.084.1

6.- Crankshaft seal assembly punch ..........................................................0.0F .054.0.045.1

7.- Gudgeon pin circlip assembly tool ........................................................0.0G.056.0.041.1

8.- Water pump pinion blocking tool...........................................................0.0G.053.0.098.1

9.- Engine splitting tool...............................................................................0.0G.053.0.015.1

SPECIAL TOOLS

REGULAR MAINTENANCE TABLE

Período: este período puede Km 1000 2500 5000 10000 15000 20000 25000 valorarse según los kilómetros

Months 2 6 12 24 36recorridos o el tiempo en meses

Reduction gear or crankcase oil Replace Check Check Replace Check Replace Check Suspensions Check Check Check Check Check Tighten all fastenings Check Check Check Check Check Check Check Electrical connections Check Check Check Check Check Check Check Spark plug Clean Adjust Replace Replace Replace Replace Replace Carburettor Adjust Adjust Adjust Adjust Adjust Adjust

Clean Clean Clean Clean Clean Clean Water pump drive belt Replace Variable speed drive rollers Check

drive belt transmission Replace Oil filter Check Replace Check Replace Check Air filter Clean Clean Clean Clean Clean Brakes / hose / pads Check Check Check Check Check Brake equipment Check Check Brake fluid EVERY 2 YEARS EVERY 2 YEARS Tyres Check Check Check Check Check Tyres pressures Check Check Check Check Check Check Check Fuel or oil hoses Check Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate Cylinder head nuts Tighten up Tighten up Inlet valve reeds Check Check

Period: the period may be calculated by kilometres run or by time in months

PART NAME TORQUE SETTING

(Nw x m.)

BRAKE SHOE ROTATION SHAFT 8M125 17 - 19 LOCTITE CYLINDER STUD 6M100 STUD 10 - 12 CRANKCASE HALVES 6M100 SCREW 9 - 10 LOCTITE CYLINDER HEAD 6M100 NUT 10 - 12 INLET MANIFOLD VALVE BRACKET 4M70 SCREW 1 - 2 LOCTITE CRANKCASE INLET MANIFOLD 6M100 SCREW 9 - 10 LOCTITE OIL PUMP 5M80 SCREW 4 - 5 LOCTITE COIL TO BASE PLATE 6M100 SCREW 8 - 10 LOCTITE BASE PLATE TO CRANKCASE 6M100 SCREW 8 - 10 LOCTITE MAGNETO 10M100 NUT 35 - 40 LOCTITE STARTER MOTOR 6M100 SCREW 9 - 10 LOCTITE FAN TO MAGNETO 6M100 SCREW 8 - 10 LOCTITE ENGINE BRACKET PLATE A.E. 6M100 SCREW 9 - 10 LOCTITE LEFT HAND SIDE CRANKSHAFT 10M100 NUT 35 - 40 LOCTITE REDUCTION GEAR COVER 6M100 SCREW 9 - 10 LOCTITE PULLEY SHAFT 10M100 NUT 35 - 40 LOCTITE PLASTIC OIL FILLER CAP 14M150 CAP HAND TIGHT LEFT HAND CRANKCASE COVER 6M100 SCREW 9 - 10 LOCTITE OIL DRAIN PLUG 8M125 SCREW 17 - 19 CYLINDER SLEEVE 6M100 SCREW 9 - 10 FRONT WHEEL 12M150 NUT 50 - 60 REAR WHEEL 16M150 NUT 100 - 105 SWINGING ARM 10M150 NUT 40 - 45 SHOCK ABSORBER UPPER/LOWER 10M150 NUT 40 - 45 HANDLEBAR 8M125 SCREW 20 - 25 EXHAUST PIPE TO CYLINDER 6M100 SCREW 8 - 12 EXHAUST PIPE - INTERMEDIATE 6M100 NUT 8 - 12 EXHAUST PIPE TO CRANKCASE 10M150 SCREW 40 - 45 FORK LEG CLOSURE 6M100 NUT 8 - 12 STEERING 25M100 NUT 70 - 90 FRONT BRAKE 8M125 SCREW 20 - 25 KICK START PEDAL 6M100 SCREW 08 - 12 LOCTITE SILENCER PROTECTOR 4M70 SCREW 1 - 2 LOCTITE

TORQUE SETTINGS

HUNTER MODELS Stripping the fork legs

- Withdraw the two screws from the brake caliper.

- Withdraw the front wheel axle nut and slacken the lock screw.

- Withdraw the front wheel axle, the wheel DISTANCE PIECE, and leave the transfer box and the separator hanging free.

- Withdraw the fork protection plate screw so as to be able to extract the external fork leg cap.

- Loosen the 10 x 25 screw from the fork plate and while pushing upwards on the fork leg, release the fork bar securing clip.

- Withdraw the fork leg from the vehicle.

Both fork legs are the same.

Stripping the left or right hand fork bar

- Withdraw the safety circlip.

- Undo the fork leg tube cap and seal.

- Drain the hydraulic fluid from the bar.

- Extract the fork leg spring.

- Loosen and extract the fork leg screw.

- Withdraw the hydraulic tube and the bar from the fork leg.

- Extract the dustguard, the seal securing circlip, and finally the seal.

Note: Clean thoroughly all the parts which are

to be re-fitted; it is mandatory under all circumstances to replace the O-rings and seals.

Re-assembly of the fork leg

- Fit the seal into the fork leg size 30-40-7/9. Using special tool 0.0H.054.0.045.1 and insert the seal securing circlip.

- Insert the hydraulic tube inside the fork bar.

- Insert the bar inside the fork leg, fit the fork spring and tighten the 10 x 25 screw using a copper washer and Loctite to a torque of 35- 40 Nw x m.

- Re-fill using 80 cc of AGIP FORK SAE10W hydraulic oil.

FRONT FORKS

- Insert the fork leg tube cap with the Oring seal, the safety circlip and the dustguard.

- Assemble the fork leg into the vehicle.

- Insert the complete fork leg assembly into the fork plate.

- Fit the safety circlip and the exterior fork leg cap.

- Tighten the fork plate securing screw.

- Tighten the mudguard/fork plate protector securing screw.

- Locate the wheel axle, the transfer box, the transfer box bushing, the wheel, and fit the brake caliper onto the brake disc; then the distance piece, the washer, the spring washer and nut, tightening to a torque of 50 - 60 Nw x m.

- Tighten the fork leg closure screw to a torque of 8 - 12 Nw x m.

- Locate the two brake caliper securing screws (8 x 60) to a torque of 20 - 25 Nw x m. using Loctite. Finally turn the wheel and operate the brake lever.

PADDOCK MODELS Stripping the fork legs

- Withdraw the four mudguard screws and remove the mudguard.

- Slacken off the wheel axle nut, withdraw the washer, loosen the 2 front brake caliper screws, loosen the locking screw, extract the wheel axle, the axle distance piece and leave the transfer box and the separator hanging free.

Stripping the left hand fork bar

- To disassemble the left hand fork bar without stripping the fork the following procedure should be followed:

- Remove the dustguard and extract the safety circlip.

- Withdraw the two screws securing the bag carrier hook.

- Withdraw the seven screws securing the inner shield and remove the inner shield.

- Drill a hole using a 15 mm drill through the fork plate protector so as to be able to insert a tube spanner and loosen the 6 x 100 nut and washer; this way it is possible to withdraw the left hand fork leg, with the hydraulic cartridge with bushing and silentbloc, the boss, the rubber stop spring and the guide washer.

If the hydraulic cartridge loses oil it must be replaced, since it cannot be repaired.

Right hand fork bar

- Remove the dustguard and the safety circlip.

- Withdraw the right hand fork leg, the lower spring washer, the rubber stop and the spring.

This fork leg should be filled with AGIP GR MU 3 type grease only.

Re-fitting the two fork legs is carried out in the reverse order from stripping.

VAMOS MODELS Stripping the fork legs

-Withdraw the 2 front brake caliper screws (“separate the caliper”).

- Remove the wheel axle nut, the spring washer and the washer.

- Withdraw the wheel axle, the transfer box bushing and the whole transfer box assembly.

- Loosen the end piece screws, and withdraw the end pieces.

- Extract the fork leg dustguard and the safety circlip.

- Withdraw the fork leg, the stop and the spring.

When re-assembling, carry out the same procedures in reverse order.

The fork legs should be filled with AGIP GR MU 3 type grease.

STRIPPING

- Remove the luggage carrier ( 4 screws).

- In PADDOCK models separate the electrical connectors on the turn indicators.

- The left hand footrest cover (1 screw).

- The left hand side panel (2 screws).

- The right hand footrest cover (1 screw).

- The right hand side panel (2 screws).

- Raise the saddle.

- Remove the side panels (5 screws).

- Remove the oil reservoir cap.

- Remove the fuel tank filler cap.

- Remove the anti-freeze reservoir cap on PADDOCK-LC models.

- Remove the helmet carrier box (6 screws).

- Remove the rear brake cable nut.

- Remove the rear brake guide stop (1 screw).

- Remove the engine earth screw.

- Remove the throttle cable union.

- Disconnect the electrical connectors for the magneto, the stop light, the choke, the starter, the high tension coil and the coil earth cable.

- On the LC models, also disconnect the thermocontact spade connector.

- Disconnect the two pipes from the connector on the carburettor: the fuel pipe and the vacuum line.

- Disconnect the oil hose at the reservoir outlet.

- In PADDOCK-LC models extract the antifreeze drain plug.

- Remove the cooling hoses where they connect to the antifreeze reservoir.

- Remove the 2 fixing screws which secure the engine to the frame.

- Remove the 1 shock absorber screw.

- Separate the engine from the frame.

WITHDRAWING THE ENGINE FROM THE FRAME

- Remove the exhaust pipe.

- Remove the filter box together with the inlet pipe and the rear mudguard.

- Withdraw the rear wheel nut and remove the rear wheel.

- Withdraw the centre stand spring, the pin, the central shaft, and the stand.

- On PADDOCK-LC models, remove all hose clips, radiator hoses, and the radiator.

- Remove the fan (2 screws).

- Remove the sleeve cover.

- On PADDOCK-LC models, first withdraw the antifreeze outlet connector on the cylinder head (2 screws and gasket).

- Remove the carburettor together with the reed valve (4 screws).

- Remove the magneto nut using the special tool

0.0G.0.530.001.1.

- Remove the magneto using the special magneto extractor tool 0.0G.053.0.015.1.

STRIPPING THE ENGINE

- Remove the stator (2 screws): in order to be able to extract the stator completely, the base plate should be withdrawn (3 countersunk Allen head screws) using an impact screwdriver; withdraw the grommet and the magneto key.

- Withdraw the spark plug NGK 8 HS or CHAMPION L-78-C.

-On LC models, NGK B9 ES or CHAMPION N-2-C.

- Withdraw the cylinder head (4 screws) and the cylinder head gaskets.

- Withdraw the cylinder, the cylinder gasket, the piston, and the cylinder studs.

- Remove the oil pump (2 screws).

- Remove the pump drive gear wheel, the safety ring, the washer, the gear wheel, the key and the safety circlip “replace the gear wheel with a new one”.

- Withdraw the cooling hose from the pump to the radiator (2 screws) and the O-ring.

- Remove the left hand side crankcase cover or clutch cover (10 screws).

- Loosen the variable speed drive nut, blocking the connecting rod using special tool

0.0G.056.0.037.1.

- Extract the nut, the washer, the starter boss, the drive washer, the drive pulley, the washer, the bush, the sliding weight hub, with the plate, and the 6 rollers.

- Extract the washer, the starter gear wheel, the washer and the bush.

- On L.C: models (“only withdraw the starter gear wheel, there are no washers or bushes”.

- Remove the clutch belt.

- Loosen the clutch hub nut using the special tool

0.0G.053.0.001.1 and remove the nut, the washer, the hub, and the clutch club.

- Loosen the reduction gear oil drain plug with the washer and remove.

- Loosen and remove the 6 screws to the reduction gear box cover, and immediately remove the reduction gear cover complete with the clutch pulley shaft and the gasket.

- Withdraw the washer, the gear wheel shaft and the intermediate shaft.

- Withdraw the water pump drive gear nut using special tool 0.0G.053.0.098.1.

- Withdraw the pump drive gear and the pump drive pinion together with the toothed belt.

- Withdraw the water pump body locking piece (2 countersunk Allen head screws).

- In order to extract the water pump body, the following special tools are required: 0.0G.056.0.042.1 and 0.0G.056.0.036.1.

- Loosen and remove the bendix starter pinion bracket (2 screws).

- Loosen and withdraw the 6 securing screws for the right hand crankcase half.

- In order to split the crankcase halves, it is necessary to make use of the special tool

0.0G.053.0.015.1.

- Next separate the crankcase halves.

- Loosen the 2 screws to extract the starter motor, the gasket and the O-ring.

- Withdraw the rear brake shoes.

- Loosen and remove the rear wheel bearing locking piece “Use an impact hammer to loosen these screws”.

- Withdraw the wheel axle seal, and using special tool 0.0H.054.0.045.1 and heating the part to a temperature of 80ºC by means of a hot air paint stripper, extract the rear wheel axle bearing.

- Remove the crankshaft seal in the left hand side crankcase using special tool 0.0H.054.0.058.1.

- Extract the rear brake lever and the brake operating arm.

- Extract the crankshaft from the crankcase half or right hand crankcase half using special tool

0.0G.053.0.015.1.

- Extract the crankshaft seal in the right hand side crankcase.

- Extract the crankshaft bearing from the crankcase half using special tool 0.0H.054.0.058.1, after heating the part to a temperature of 80º C with a hot air gun.

- If the bearings remain on the crankshaft they should be removed using a tool similar to the Kawasaki tool reference number 57001-158, thus withdrawing the bearings from the crankshaft.

- Withdraw the pulley shaft from the reduction gear cover, and extract the 2 bearings from the reduction gear cover by applying heat.

- Assembly of the wheel shaft bearing: heat up the housing by means of a hot air gun to approximately 80º C and use special tool number

0.0F. 054.0.045.1 to insert the bearing number 6204-2RS1.

- Fit the wheel shaft bearing locking piece with the 2 screws using a thread sealer (such as Loctite

243) and tighten to a torque of 9 - 10 Nw x m.

- Assembly of the pulley shaft bearing: Heat up the left hand side crankcase half to approximately 80º C, insert the bearing, number 6201-C3, and push fully home.

- Fit the rear wheel seal using special tool number

0.0F.054.0.045.1.

- The seal should be fitted with the lip facing inwards, or alternatively while it is being fitted the retaining spring should be visible and when it is home it should be just at the same level as the crankcase.

- Fit the washer and intermediate shaft.

- Fit the wheel shaft “taking great care not to

damage the seal spring”.

- Offer up the reduction gear cover gasket and check the locating pins for the reduction gear cover.

- Reduction gear cover: fit the bearings in the reduction gear cover using special tool

0.0F.054.0.045.1, after heating it up to approximately 80º C. First insert the bearing number 6203-C4, then the bearing number 6204-C3. Finally, heat up the core of this bearing so as to be able to fit the pulleyshaft.

ASSEMBLY OF THE ENGINE

- Using special tool number 0.0F.054.0.045.1 insert the pulley cover shaft seal.

- Fit the washer onto the intermediate shaft and locate the reduction gear cover using 4 screws size 6 x 25 and 2 screws size 6 x 30. Use thread seal (such as Loctite 243) and tighten to a torque of 9 - 10 Nw x m.

- Fit the oil drain plug using a new washer and tighten to a torque of 17 - 19 Nw x m.

- Fill the crankcase with 110 cc of AGIP GEAR SYNTH SAE 75w/90 oil. Fit the oil filler cap screw with an O-ring and tighten manually.

- Fit the rear brake operating arm using grease, followed by the foam, the brake shoe wear turn indicator cover, the brake lever, the screws and nut.

- Heat up the crankshaft seating in the right hand crankcase half using a hot air gun to approximately 80º C, and insert the crankshaft bearing 6204-px2 v4 using special tool 0.0F.054.0.045.1.

- Measure the lateral play at the connecting rod

big end using feeler gauges: the maximum permissible play is 0.35 to 0.60 mm.

- Verification of the crankshaft counterweights.

39. - 03mm

- 04 mm

- Place the crankshaft on blocks and check the radial play at the bearing seating.

Service limit 0.04 mm. Both sides

- Heat up the bearing core using a hot air gun.

- Fit the crankshaft into the left hand crankcase half.

- Check the 2 crankcase half centring guide pins, and locate the crankcase gasket using AGIP GR

MU 3 type grease.

CRANKSHAFT INSPECTION

- After heating up the seating in the right hand side crankcase half to 80º C, fit the crankshaft bearing using special tool 0.0F.054.0.045.1. The bearing is number 6204 px2 v4.

- Heat the bearing core in the right hand crankcase half with a hot air gun so as to be able to close the crankcase with 6 screws: 4 6 x 35

1 6 x 40 1 6 x 50

Use thread seal Loctite 240 type and tighten to a torque of 9 - 10 Nw x m.

- Fit a wedge in between the crankshaft counterweights in order to centre the crankshaft.

The crankshaft should be centred to the following tolerances:

Minimum 0.30 Maximum 0.84

- Fit the new crankshaft seal in the left hand crankcase half with guide bush 0.0F.053.0.084.1. and special tool 0.0F.054.0.045.1.

ASSEMBLY OF RIGHT HAND

CRANKCASE BEARING

Stripping

- Unscrew the water pump “the water pump has a left-handed screw”

- Withdraw the two rubber O-rings

- Using special tool 0.0H.056.0.025.1 and a rubber mallet, strike the pump drive shaft in order to extract it complete with its two bearings.

- Extract the pump drive body seal

- Withdraw the 10 mm shim washer. Using special tool 0.0F.054.0.045.1, place the

bearing on top and using special tool

0.0H.056.0.025.1 strike the shaft with a rubber mallet to extract.

- Withdraw the bearing, the 10 mm shim washer and the shaft, and finally withdraw the circlip from the shaft.

Assembly

- Fit the circlip to the pump drive shaft.

- Using special tool 0.0F.054.0.045.1, place the first bearing on the tool, then the washer, the second bearing, the washer and then assemble the shaft using a rubber mallet.

- Fit the pump drive body on the special tool

0.0F.054.0.045.1.

- Next apply heat to the pump drive body and fit the pump drive shaft with the bearings.

WATER PUMP

- With the aid of special tool 0.0H.056.0.025.1, insert the shaft in the pump drive body.

-Next fit the seal using special tool

0.0H.056.0.025.1. The spring of this seal faces outwards.

- Fit the fan.

- Fit the two O-rings.

- Fit the water pump drive unit with great care into the left hand crankcase.

- Fit the water pump unit locking piece with 2 screws 5 x 12.

- Fit the bendix pinion.

- Fit the starter motor support bracket.

- (2 screws 6 x 30 tightened to a torque of 9 - 10 Nw x m. using Loctite type 240).

- Fit the pump pinion assembly with the toothed belt and the pump drive pinion and tighten down the nut for this assembly.

- To fit the pump pinion, use should be made of the special tool 0.0G.053.0.098.1 and tightened to a torque of 10 Nw x m.

- Fit the starter motor gear wheel “with the concave side facing outwards”.

- The working surfaces of the pulleys should be carefully inspected where the drive belt runs: if these faces are deformed or show signs of wear, the useful life of the drive belt is extremely seriously affected.

- Disassemble the variable speed unit withdrawing the sliding weight plate.

- Confirm that the 6 rollers maintain their original profile and show no signs of wear of abrasion which might affect the correct operation of the variable speed unit.

- Check that the guides mounted on the sliding weight plate show no signs of wear, which would cause excessive noise and problems in the correct operation of the unit.

- Check the bronze bush in the sliding weight hub and that the bush is tightened to the correct torque.

- The transmission is by trapezoidal belt, the maximum width of which under working conditions must equal 16 mm, in the HUNTER, PADDOCK, PADDOCK-LC engines, and 15 mm in the VAMOS MONOBLOC engines.

- The belt must be replaced every 6,000 kms.

- Fit the variable speed unit with 6 rollers the sliding weight plate with the guides, and then fit the hub boss bushing, placing the variable speed unit onto the left hand side of the crankshaft.

- Fit the 20 x 16 x 1 mm friction washer.

- Next fit the drive pulley, the drive washer, the starter boss, the washer, and the nut.

- Use special tool 0.0G.056.0.037.1 to tighten down the variable speed unit nut, blocking the connecting rod; tighten to a torque of

35 - 40 Nw x m. using Loctite thread seal.

ASSEMBLY OF SLIDING WEIGHT HUB

Stripping:

- In order to disassemble the clutch assembly, the special locking tool 0.00.052.5.324.0 should be used, and the clutch nut is released using a 36 mm socket spanner.

- Disassembly of the clutch shoe plate:

- The clutch shoe plate does not usually require to be disassembled since the wear on the shoes in minimal. But if it should prove necessary to disassemble the clutch shoe plate, the position of the shoes as they are originally placed should be marked, because they are balanced: the three locking clips should also be placed from the inside towards the outside, so that the clutch continues to operate normally. Check the three springs.

The service limit on the shoes is 2 mm.

Assembly:

- Take the moving pulley and insert the 2 seals (33 x 39 x 4).

- Using the special tool 0.0F.054.0.045.1, the two grease retaining rings, fit the moving pulley into the fixed pulley, checking that the lip of the seal is not damaged when the pulley is inserted.

- Insert the three guide pins in the slot on the moving pulley.

- Fill the spring guide bush with AGIP GR MU 3 grease and fit, then the spring slider bushing, the spring, the spring guide boss, the clutch shoe plate and the nut.

- Using special tool 0.00.052.5.324.0 and a 36 mm socket spanner tighten up to a torque of 65 - 70 Nw x m.

- Fit the clutch assembly onto the pulley shaft together with the toothed belt.

CLUTCH ASSEMBLY

- Fit the clutch hub onto the pulley shaft, the washer, and the nut.

- Using special tool 0.0G.053.0.001.1 lock the clutch hub and tighten up the nut to a torque of

35 - 40 Nw x m. sealing the thread with Loctite

243.

- The service limit for the clutch hub is:

112.5 mm.

- Disassembly of the starter sector:

- Withdraw the starter protector plate (three screws 6 x 12).

- By operating the starter pedal it is posssible to extract the starter sliding pinion complete with the spring.

- Withdraw the starter pedal, the circlip, and the washer, so as to be able to extract the starter shaft, the stop boss, the spring retainer ring, and the spring.

MODEL

BELT

ROLLERS Ø CLUTCH SHOES SPRIN REDUCTION

GEAR

TYRE

Length

mm. Grams mm. Grams

DREBI 716 6,583X6= 107 400 24 Kg 12/55X13/37 100/80X10" VAMOS 39,5 42 mm.

VAMOS 716 6,583X6= 112 570 26 Kg 12/43X14/45 100/80X10"

CHINA 39,5 39 mm.

HUNTER 836 6,583X6= 112 570 26 Kg 12/43X12/49 130/90X10"

39,5 39 mm.

PADDOCK 836 6,583X6= 112 570 26 Kg 12/43X13/49 130/60X13"

39,5 39 mm.

PADDOCK-LC 836 6,333X6= 112 570 24,5 Kg 12/43X14/48 130/60X13"

38,0 41 mm.

REDUCTION GEAR

LEFT HAND CRANKCASE COVER

Assembly of the left hand side crankcase cover

- Insert the spring.

- The spring retainer washer.

- Starter sector stop bush.

- Starter shaft “with O-ring and corium 55 type

grease”.

- Washer and circlip.

- Starter pedal.

- Bendix pinion and spring, applying grease to the sliding pinion.

- Fit the starter protection plate (3 screws 6 x 12 using Loctite thread seal).

- Fit the left hand crankcase centring pins.

- Fit the left hand crankcase cover gasket.

- Fit the left hand crankcase cover.

(10 screws : 8 of 6 x 25 and 2 of 6 x 30, apply Loctite and tighten to a torque of 9 - 10 Nw x m.)

- Using special tool 0.0F.054.0.045.1, fit the seal 20 x 38 x 7 on the right hand side of the cranks-

haft.

- Fit the circlip, the pump drive guide pin in the seating on the crankshaft, fit the pump drive, the washer, and the circlip.

- Fit the oil pump with 2 screws 5 x 15 and tighten to a torque of 4 - 5 Nw x m. “fill this part with AGIP GR MU 3 type grease”.

- Replace the 18.9 x 30 x 5 seal in the pump drive closure cover, using a new part.

- Pass the stator cable through the closure cover, and fit the grommet.

- Fit the cover using 3 screws 6 x 16 and tighten to a torque of 9 - 10 Nw x m.

- When locating the closure cover, it should be positioned with the exit slot for the cables from the base plate, at the top.

- Fit the stator with 2 screws 6 x 25 and tighten to a torque of 8 - 10 Nw x m.

- Fit the magneto key, the magneto, the washer, and the nut. Using special tool 0.0G.056.0.037.1, to block the connecting rod, tighten the nut to a torque of 35 - 40 Nw x m. sealing the thread with

Loctite.

- Fit a new cylinder gasket.

- Fit the cage bearing to the connecting rod little end.

PISTON RINGS

- Fit the piston rings into the cylinder and use the piston to push them a little way in, until they are perpendicular to the longitudinal axis of the cylinder.

- Measure the gap between the ends of the piston rings using feeler gauges.

The maximum permissible value is 0.5 mm.

PISTON

- Measure the exterior diameter of the piston at a point situated 15 mm from the base of the piston.

- Calculate the play between the cylinder and the piston.

The service limit is 0.06 mm.

Fit the piston rings onto the piston.

- “First fit the expansion ring, and then the lower ring”. It is rectangular in section, and finally, fit the upper piston ring “which has a trapezoidal section”.

- Fit the piston and keep the arrow on the upper surface of the piston facing towards the exhaust port.

- The piston is assembled onto the connecting rod by first inserting the little end cage bearing into the little end of the connecting rod, then the gudgeon pin and securing it by means of the circlips, using special tool 0.0G.056.0.041.1.

- When fitting the cylinder it is recommended to apply a little oil to the part, and to the piston rings and to the piston so as to make assembling the cylinder over the piston easier. The recommended oil is that used for the fuel mixture.

CYLINDER HEAD, CYLINDER, AND PISTON

- The cylinders of the monobloc models cannot be rectified, and there are no oversizes. There are only families of cylinders and pistons, which go in steps of 0.005 mm.

- When replacing the piston, the family identification stamped on the cylinder should be identified, and a piston of the same letter as on the cylinder should be used.

Table of tolerances for cylinder and piston

CYLINDER HEAD

- Check the contact surface (the sealing surface) of the cylinder head by resting it on a surface plate; using a feeler gauge check that there is no greater gap than 0.05 mm.

- For the engine to run properly it is very important that the cylinder head-cylinder joint, and the sheathing should be perfectly gas-tight.

- If the gap between the two parts is higher that the value quoted above, then it will be necessary to grind down the surface on abrasive paper resting on a surface plate, moving it in figures of eight as shown in the diagram.

- Models HUNTER, PADDOCK, and VAMOS: in these models the cylinder head gasket should be fitted with the convex exterior border facing upwards.

TABLE OF FAMILIES

FAMILY PISTON CYLINDER PLAY

ASSO SP348

A 40,95

+ 0.004

40,975

+0.005

- 0 - 0

B 40,955

+0.004

40,980

+0.005

- 0 - 0

C 40,960

+0.004

40,985

+0.005

- 0 - 0

D 40,965

+0.004

40,990

+0.005

- 0 - 0

From

0,021

0,030

- In the case of the PADDOCK-LC model the gaskets must be changed every time the cylinder head is removed.

- Fit the cylinder head gaskets.

- Fit the cylinder head and tighten up the four 6 mm nuts to a torque of 10 - 12 Nw x m. using a torque spanner.

- Fit the copper gasket and the thermocontact to a torque of 18 - 20 Nw x m.

- Fit the spark plug and tighten to a torque of

18 - 20 Nw x m.

CARBURETTOR MANIFOLD

- Check that there are no cracks in the manifold.

- Check that the reeds are not broken and that they open correctly.

- Checkl that the 4 x 20 securing screws for the reed valve support are tightened to a torque of 1 - 2 Nw x m.

- Fit the reed valve in the crankcase and then the new carburettor manifold gasket.

- Fit the carburettor manifold to the crankcase: four 6 x 20 screws tightened to a torque of 9 - 10 Nw x m. using Loctite thread seal.

SPARK PLUG NGK B 8HS CHAMPION L 78C MODELS: VAMOS - HUNTER - PADDOCK SPARK PLUG NGK B 9HS CHAMPION N 2C MODELS: PADDOCK-LC

Stripping the carburettor

- Remove the choke cap.

- Renmove the 2 choke screws.

- Remove the choke.

- Wothdraw the throttle valve cover screw.

- Remove the cable from the throttle valve.

- Extract the spring and the spring guide.

- Extract the throttle valve.

- Extract the spray needle.

- Loosen and withdraw the 2 carburettor float chamber screws.

- Extract the main jet.

- Extract the idle jet.

- Remove the cold start jet.

- Remove the float pin.

- Remove the float needle.

- Remove the spray.

Inspection and maintenance of the carburettor

- It is important to check the float needle to ensure correct operation of the vehicle. Wear in the float needle may even produce flooding of fuel directly into the crankcase which may cause damage to the crankshaft seals as well as problems with the piston, the connecting rod, and cause flooding in the exhaust pipe.

CARBURETTOR FLOAT LEVEL

Model:WEBER 16.5

+1.0

-1.0 mm

Model:DELL’ORTO 14.3

+0.5

-0.5 mm

Carburettor float chamber

- When disassembling and reassembling the carburettor to carry out inspection and cleaning, attention should be paid to ensure that the gasket is correctly located in its place, and that it is not deformed or torn: if it is not perfect it should be replaced, otherwise fuel will leak out.

CARBURETTOR

Cleaning the jets

- It is advisable to clean the main jet, the idle jet, and the cold start jet, as well as the airways, with a compressed air pistol.

Checking the electric choke

- Use a vernier caliper to check the choke: the length of the choke piston should be measured when cold.

- It should measure approximately 11 mm.

- To test it a battery must be used. After connecting the two terminals, wait 3 minutes, and the piston should have extended by about 4 mm, and the total measurement should be around 15 mm.

- Models like the MANHATTAN are fitted with a manual choke.

Assembly of the Carburettor

- Fit the spray

- Fit the float needle.

- Fit the float and float pin.

- Fiot the cold start jet.

- Fit the idle jet.

- Fit the main jet.

- Fit the float chamber using the 2 securing screws.

- Fit the throttle cable into the carburettor cap.

- Pass the throttle cable through the centre of the spring.

- Fit the throttle cable into the throttle valve.

- Insert the carburettor needle into the throttle valve.

- Fit the spring guide bushing.

- Insert the complete valve assembly into the body of the carburettor.

- Insert the carburettor cap screw and close the carburettor cap.

- Insert the automatic choke into the carburettor.

- Fit the locking piece, the two screws, and tighten up the automatic choke.

- Adjust the air screw (it should be opened approximately 2.5 turns).

- Install the carburettor into the engine.

Make Dell’orto Dell’orto Dell’orto Dell’orto Dell’orto Dell’orto Weber

Type

PHVA-12DD PHVA-12DD PHVA-14DD PHVA-14DD PHVA-14DD PHVA-10GD 14 OM 1AA

Diffusor 12 mm. 12 mm. 14 mm. 14 mm. 14 mm. 10 mm. 14 mm. Main jet 58 54 55 50 56 44 63

Idle jet 34 34 36 34 36 34 34

Needle type

number

A 8- 3 A 11-3 A 11-3 A 11-4 A 11-3 A 11-5 AA-3

Spray 210 FA 209 GA 208 GA 211 GA 208 GA 210 GA G 1

Throttle valve

40 30 30 40 30 30 5

Float 3,5 gr. 3,5 gr. 3,5 gr. 3,5 gr. 3,5 gr 3,5 gr. 4,5 gr.

Air screw

openin

2,5 turns 3.0 turns 2,5 turns 2.0 turns 2,5 turns 2 3/4 turns 2 turns

Cold start

jet

45 45 45 45 45 45 45

Float level

14,3

+0,5

14,3

+0,5

14,3

+0,5

14,3

+0,5

14,3

+0,5

14,3

+0,5

16,3

+1.0

-0,5 -0,5 -0,5 -0,5 -0,5 -0,5 -1,0

VAMOS

HUNTER

ITALIA

PADDOCK

HUNTER HUNTER DG MANHATTAN

HUNTER 50

Germany

Austria

Holland

MXR

HUNTER 25

Germany

Holland Finland

PADDOCK-LC

Carburettors

- Fit the oil tube from the oil pump to the carburettor.

- Fit the cylinder sleeve cover with the two securing screws (6 x 16), and tighten up to a torque setting of 9 -10 Nw x m.

- Check the oil pump bleed screw.

- It is extremely important when fitting the fan cover to check the rubber protector profile of the fan cover, since if it is broken, there will be leakage from the cooling circuit, and noise will be produced by the vibrations of the vehicle.

- Fit the fan using two 6 x 16 securing screws and tighten to a torque of 9 - 10 Nw x m. applying Loctite thread seal.

- Fit the fan cover using 2 screws (6 x 16) and 3 cross-head screws (6.3 x 19) and tighten to a torque of 9 - 10 Nw x m.

- Fit the radiator using 2 screws (6 x 60) and tighten to a torque of 9 - 10 Nw x m. and the 2 distance pieces of 35.5 mm.

- Fit the gasket and the cylinder head water outlet connector using 2 screws (6 x 20), and tighten up to a torque of 9 - 10 Nw x m. applying Loctite thread seal.

- Next fit the water hose from the connector to the radiator using 2 hose clips.

- Fit the starter motor with the supporting plate gasket, the 24 mm exterior diameter and 2.2 mm thick O-ring, using 2 screws (6 x 25) and tighten to a torque of 9 - 10 Nw x m. applying Loctite.

CYLINDER SLEEVE COVER, RADIATOR AND FILTER BOX

- Fit the cooling hose from the water pump to the radiator with an O-ring (using 1 screw 6 x 16) and tighten to a torque of 9 - 10 Nw x m. applying

Loctite.

- Then also fit 1 screw (6 x 10) to a torque of 9 - 10 Nw x m. which is secured to the crankcase, applying Loctite.

- At the lowest part of the cooling hose the cooling liquid drain screw and washer are to be found. The washer must be replaced every time the screw is touched.

- Fit the oil drain plug (8 x 16 screw) with a new washer and tighten to a torque of 17 - 19 Nw x m.

- Fill the reduction gearbox with 110 cc of AGIP GEAR SYNTH SAE 75w/90 oil.

- Next fit the filler cap and tighten to hand tight only.

- Fit the rear brake shoes, where the assembled position of the shoes must be with the bevelled edges facing outwards.

- Fit the centre stand inserting the shaft from left to right, complete with washer, pin and stand spring.

- Fit the rear wheel on its shaft, with washer and nut and tighten to a torque of 100 - 105 Nw x m.

- Fit the filter box using 2 screws (6 x 35) and tighten to a torque of 9 - 10 Nw x m.

- Tighten up the drainage tank securing screw.

- Fit the inlet tube “with the spring to the carburettor”.

- Fit the rear mudguard using 2 screws (5.1 x 18).

- Fit the exhaust pipe and silencer, using a new exhaust pipe gasket, with 2 screws (6 x 20); fit the silencer bracket using 2 screws (10 x 65) to a torque of 40 - 45 Nw x m. and the screw securing it to the rear mudguard (5 x 15).

Checking the filter box

- It is important to maintain and clean the filter properly, to ensure the proper operation of the vehicle.

- It is also very important that none of the hoses from the filter box to the carburettor or to the drainage box is disconnected, anbd that no holes are made in the filter box, since this would alter the carburation and thus adversely affect the life and duration of the engine.

- Fit the engine in the frame.

- Insert the two screws securing the engine to the frame (10 X 45), and tighten to a torque of 35 - 40 Nw x m.

- Insert the lower shock absorber screw (10 x 35) and tighten to a torque of 35 - 40 Nw x m.

- Fit the cooling hoses at the radiator water reservoir (LC models).

- Fit the fuel tubes to the fuel cock outlet, and fit them to the carburettor.

- Fit the oil hose to the carburettor and secure with a pressure clamp.

- In LC models connect the thermocontact electrical spade-connector.

- Make the connections for the magneto, the stop light, the choke, the starter, and the 2 connections to the high tension coil, and tighten up the earthing connection cable screw (6 x 25) to a torque of 9 - 10 Nw x m.

- Join the rear end of the throttle cable to the inspection cover.

- Fit the rear brake guide and the engine earth cable with 1 screw (6 x 16).

- Fit the rear brake guide stop screw (6 x 16) with the spring washer and tighten to a torque of 9 - 10 Nw x m.

- Locate the helmet carrier with the lower shield using four screws (6 x 16) and 2 screws (5 x 15).

- Fit the side panels (five crosshead screws).

- In the PADDOCK and PADDOCK-LC models pass the turn indicator cables through the hole in the left hand side panel.

- Assemble the right hand side panel to the lower shield (2 screws).

- Fit the right hand side footrest cover (1 screw).

- Assemble the left hand side panel to the lower shield (2 screws).

- Fit the left hand side footrest cover (1 screw).

- Fit the luggage carrier with four screws.

- In the PADDOCK and PADDOCK-LC models, connect up the turn indicator cables.

- Secure the luggage carrier using 5 screws (3.6 x

14), and 4 screws (2 of 8 x 35 and 2 of 8 x 60).

- Fit the fuel tank and oil reservoir filler caps, and check the oil level.

- Fill the cooling reservoir with 400 cc of antifreeze AGIP CLOSED SYSTEM PLUS 30% and screw on the filler cap.

FITTING THE ENGINE IN THE FRAME

GENERAL CHARACTERISTICS

Component Standard values Battery:

Type 12V 4 Ah Electrolyte - specific gravity 1,28 a 20º C.

System:

Type alternator and regulator Charging voltage 13,5 ± 0,5 V a 4.000 r.p.m. and lights on Coil resistance 1,1 ± 0,2 Ω a 20º C.

Lighting system:

Type Alternator and regulator Regulation voltage 13,5 ± 0,5 V a 4.000 r.p.m. and lights on

Coil resistance 0,9 ± 0,2 Ω a 20º C.

Ignition system:

Type Electronic

Magneto

Resistance of stator between Black/Red cables and earth 238 ± 30 Ω a 20º C.

High Tension coil

Secondary winding resistance 5 ± 1 KΩ Suppressor cap resistance 10 ± 1 KΩ

Switches and sensors:

Brake switches The stop light comes on after 12 mm travel of

the brake levers Fuel sensor Full: ∞Ω/ Reserve: 33 Ω Oil sensor Full: ∞Ω/ Reserve: 0 Ω

ELECTRICAL SYSTEM

BATTERY Warnings:

- Never reverse the polarity of the battery. This could cause damage to certain electronic components.

- The battery produces explosive gases. Do not make sparks or flames near the battery, and particularly when the battery is charging.

- The electrolyte in the battery contains sulphuric acid. If this acid comes into contact with the skin it causes burns. Wash the affected area with plentiful water and consult a doctor.

- In order to avoid mechanical failures do not disconnect the battery terminals or other connections unless the ignition switch is in the “OFF” position.

- Always use a slow charge whenever possible. A rapid charge should only be used in cases of emergency and then only for a short time, since it may damage the battery.

- It is advisable to remove the battery fropm the vehicle in order to charge it.

- Keep the breather tube clear of obstructions, particularly during charging.

IMPORTANT

Batteries lose charge when they are not used. Do not leave the battery for more than a month without recharging, and reduce the recharging interval to a fortnight after the first month.

Inspecting the battery

- Check periodically the level of the electrolyte, and if the level is low, add distilled water.

- Check that the density of the electrolyte in each cell is between 1.26 and 1.28. If it is below 1.26 charge the battery according to the attached table.

- If the density is low after charging the battery, or that there are variations between the different cells, the battery should be replaced.

- The density of the electrolyte varies with the temperature. Please refer to the table below.

0 5 10 15 20 25 30 35

1,21

1,22

1,23

1,24

1,25

1,26

1,27

1,28

1,29

Temperature in º C

Specific gravity

Battery Standard values

Type

12V 4 Ah

Electrolyte - specific gravity

1,28 a 20º C.

Charging amperage

0.4 Amps maximum.

Charging coil resistance

1,1 Ω±0,2 a 20º C.

Charging the battery for the first time

- Cut or extract the breather tube seal and fit the tube.

- Remove the plugs and fill the battery with electrolyte with a density of 1.28 at 20º C.

- It is extremely important to check the density of the electrolyte before charging the battery.

- Leave the battery to rest for about one hour after filling. Then adjust the level of electrolyte by adding electrolyte.

-Then connect the charger for 10 hours at

0.4 Ah., matching the polarities (connecting the + and the - of the charger to the + and the - of the battery).

Normal charging

- Remove the battery from the scooter. Clean the battery with plentiful water, but making

sure that water does not enter the cells.

- Inspect the cells, and add distilled water to the level indicated on the battery.

- Connect the charger, taking care to match the polarities.

- Charging current: 0.4 maximum.

- Decide the charging time according to the attached table.

Red +

Black -

1,28 1,23 1,18 1,13 1,08

Specific gravity at 20ºC

246810121416

Hours charging required

Schematic and battery charging control

4 AMP. FUSE

BATTERY

12V 4Ah

BATTERY

ACCESORIES

R/Or

IGNITION KEY

Wh/R

REGULATOR / RECTIFIER

Wh/Y

TO SWITCH LIGHTS

Y/Gr

MAGNETO

R Y Y/Gr R/Bk Wh/Y Wh/R

= RED = YELLOW = YELLOW/GREEN = RED/BLACK = WHITE/YELLOW = WHITE/RED

Alternator voltage test at medium revs

Tester White / Yellow White / Red

Connections Cable Cable

Earth Minimum voltage 25V AC Minimum voltage 30V AC

Alternator resistance Test

Tester White / Yellow White / Red

Connections Cable Cable

Earth 0,9 Ω±0,2 1,1 Ω±0,2

Regulator Test at medium revs

Tester Alternating current Positive cable

Connections Yellow cable Red cable

Earth 13,5 V ± 0,5 13,5 V ± 1

Function of the colours

Colour Function

Green / Black stopping the engine and feeding the ignition

Yellow / Green Earth

Green Coil feed

Black / Red Spark lead

IGNITION KEY

GREEN/BLACK

BLACK/RED

YELLOW/GREEN

SPARK PLUG

ALTERNATOR

SCHEMATIC AND IGNITION CIRCUIT CONTROL Service information

- The ignition timing does not need any maintenance.

- The spark is distributed at 20 º before TDC at 4,000 rpm.

Schematic wiring diagram

CHECKING THE IGNITION Inspecting the magneto

- Remove the inspection cover, so as to be able to reach the magneto connectors.

- Disconnect the Black /Red feed cable from the coil and the 2-way connector in the White/Red and the White/Yellow cables.

- Check that the resistance values are in line with the following tables:

The values for consulting the table should be

read between 20º and 30º C.

- If the actual values are not the same as those on the table, check the wiring before replacing the mageto.

Inspecting the coil

- Withdraw the spark plug cap.

- Check the resistance of the secondary winding of the coil between points A and B.

- The correct value between A and B: 5 - 6 kΩ.

- If the value of the resistance of the secondary winding and the magneto are correct, the coil assembly should be replaced.

Checking the spark plug cap

- Check the value of the resistance between the terminals of the spark plug cap.

- The correct value of the resistance: 9 - 11 kΩ.

SWITCHES AND SENSORS Ignition switch

- Remove the panels so as to be able to reach the ignition lock connectors.

- Remove the ignition lock to carry out the continuity check as in the attached diagram.

Code and function of the colours

BL - Blue.............Earth input

Wh/R - White/Red....Engine stop

Or - Orange ........

Output and for battery accessories

Gr - Green ..........Input and Battery

- If the continuity test is not satisfactory, replace the ignition lock.

- If the test is satisfactory, check the general condition of the cables in the wiring.

BI R/Wh Or Vi

ON OFF LOCK

Black/Red White/Red White/Yellow

Earth

238 Ω 1,1 Ω 0,9 Ω

±10 % ± 15% ± 15%

Connection of lighting switch, turn indicators and horn

- Remove the panel so as to be able to disconnect the switch connectors.

- If the continuity test is not satisfactory, replace the switch.

- If the test is satisfactory, check the general condition of the cables in the wiring.

PADDOCK-LC Switch

Codes and Functions of the colours

Y/Gr - Yellow/Green.Earth

Bk - Black .............Horn

P - Pink...............Rear right hand turn indicator

Or - Orange ..........Turn indicator common line

Vi - Violet.............Rear Left hand indicator

Bl - Blue...............Headlight - High beam

Wh/Y - White/Yellow..Headlight - Dipped beam

Br - Brown............Lighting switch supply

Horn Left Turn indicator Right Turn indicator High Beam Dipped Beam Colours Y/Gr Bk Vi Or P Br Wh/Y BI

Horn Left Turn indicator Right Turn indicator Colours Y/Gr Bk Vi Or P

Lighting Switch and Electric Start

Codes and functions of the colours

Front and rear brake switch

- Disconect the terminals of the press switch and check continuity between contacts A and B.

- With the press button closed, the resistance is infinite, and with the press button at rest, the value of the resistance is 0 Ω.

Side Stand switch

- Disconnect the 2-way connector situated below the saddle.

- Check continuity between the Yellow/Green and Green/Black cables.

Values of the resistance

Stand deployed 0 Ω Stand closed ∞Ω

Oil reserve sensor

- Remove the plastic caps from the reservoirs, and extract the tank sensor.

- Disconnect the terminals from the sensor and check continuity beween terminals (1) Yellow/Green cable and Blue/Black cable.

Values of the resistance

Position A 0 Ω Position B ∞Ω

Fuel tank reserve sensor

- Remove the plastic caps from the tanks, and remove the sensor from the tank.

- Disconnect the sensor terminals and check continuity between terminals (1) Yellow/Green cable and White/Blue cable

Values of the resistance

Position A 33 Ω Position B ∞Ω

Starter Lights Colours Y/Gr Wh/Bk Y Br

Y/Gr - Yellow/Green .....Earth

Wh/Bk - White/Black .......Relay Operation

Y - Yellow ....Supply

Br - Brown....Rear light and lighting dip switch

SCHEMATIC AND CARBURETTOR HEATING

CONTROL

Checking the thermostat

- Check that power reaches the thermostat by connecting a lamp between the Yellow/Green and Yellow cables.

- In order to check the output of the black cables, it is necessary to lower the temperature of the thermostat to 5º C and then check the output between the black cableS with a 12V lamp.

Checking the thermoresistance of the carburet-

tor

- Check the resistance of the PTC at a temperature of between 15º and 20º C.

Values of the resistance = 8 Ω±3

PTC CONTROL THERMOSTAT

Y/Gr

BLACK

YELLOW

ALTERNATING CURRENT SUPPLY

FROM REGULATOR

PTC CARBURETTOR HEATING

ECHEMA ELECTRIQUE PADDOCK-LC

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE HUNTER

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE MANHATTAN USA

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ANNEXE

PREDATOR-LC - CAT - WVTA Models PREDATOR O2 - CAT - WVTA Models ATLANTIS - CAT - WVTA Models ATLANTIS-LC - CAT - WVTA Models ATLANTIS 100 Models

REGULAR MAINTENANCE TABLE

Período: este período puede Km 1000 2500 5000 10000 15000 20000 25000 valorarse según los kilómetros

Months 2 6 12 24 36recorridos o el tiempo en meses

Reduction gear or crankcase oil Replace Check Check Replace Check Replace Check Suspensions Check Check Check Check Check Tighten all fastenings Check Check Check Check Check Check Check Electrical connections Check Check Check Check Check Check Check Spark plug Clean Adjust Replace Replace Replace Replace Replace Battery (with maintenance) Check Check Check Check Check Check Carburettor Adjust Adjust Adjust Adjust Adjust Adjust

Clean Clean Clean Clean Clean Clean Water pump drive belt Replace Variable speed drive rollers Check

Drive belt transmission Replace Oil filter Check Replace Check Replace Check Air filter Clean Clean Clean Clean Clean Brakes / hose / pads Check Check Check Check Check Braka equipment Check Check Brake fluid EVERY 2 YEARS EVERY 2 YEARS Coolant Check Check Check Check Check Check Check Tyres Check Check Check Check Check Tyres pressures Check Check Check Check Check Check Check Fuel or oil hoses Check Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate

and greasing and greasing and greasing and greasing and greasing

Cylinder head, cylinder, piston Clean Segments piston Replace Check Check Cylinder head nuts Tighten up Tighten up Inlet valve reeds Check Check Rear suspension links Clean Clean

Greasing Greasing

Speedometer transfer box Clean Clean

Greasing Greasing

Period: the period may be calculated by kilometres run or by time in months

PART NAME TORQUE SETTINGS

(Nw x m)

SHOE ROTATION SHAFT 8M125 17 - 19 LOCTITE CYLINDER STUD 6M100 STUD 10 - 12 CRANKCASE SECURING SCREWS 6M100 SCREW 9 - 10 LOCTITE CYLINDER HEAD 6M100 NUT 10 - 12 INLET VALVE MANIFOLD BRACKET 4M70 SCREW 1 - 2 LOCTITE CRANKCASE INLET MANIFOLD 6M100 SCREW 9 - 10 LOCTITE OIL PUMP 5M80 SCREW 4 - 5 LOCTITE COIL TO BASE PLATE 6M100 SCREW 8 - 10 LOCTITE BASE PLATE TO CRANKCASE 6M100 SCREW 8 - 10 LOCTITE MAGNETO 10M100 NUT 35 - 40 LOCTITE STARTER MOTOR 6M100 SCREW 9 - 10 LOCTITE FAN TO MAGNETO 6M100 SCREW 8 - 10 LOCTITE ENGINE A.E. PLATE SUPPORT BRACKET

6M100 SCREW 9 - 10 LOCTITE LEFT HAND CRANKSHAFT 10M100 NUT 35 - 40 LOCTITE REDUCTION GEAR COVER 6M100 SCREW 9 - 10 LOCTITE PULLEY SHAFT 10M100 NUT 35 - 40 LOCTITE PLASTIC OIL FILLER CAP 14M150 CAP HAND TIGHT LEFT HAND CRANKSCASE HALF COVER

6M100 SCREW 9 - 10 LOCTITE OIL DRAIN PLUG 8M125 SCREW 17 - 19 CYLINDER CASING COVER 6M100 SCREW 9 - 10 FRONT WHEEL 12M150 NUT 40 - 45 REAR WHEEL 16M150 NUT 100 - 105 SWINGING ARM 10M150 NUT 40 - 45 UPPER / LOWER SHOCK ABSORBER 10M150 NUT 38 - 40 CLIP-ON HANDLEBARS 8M125 SCREW 20 - 25 EXHAUST PIPE TO CYLINDER 6M100 SCREW 8 - 12 EXHAUST PIPE TO INTERMEDIATE SUPPORT

6M100 NUT 8 - 12 EXHAUST PIPE TO CRANKCASE 10M150 SCREW 30 - 35 FORK LEG SECURING 6M100 NUT 8 - 12 STEERING 25M100 NUT 70 - 90 FRONT/REAR BRAKES 8M125 SCREW 20 - 25 STARTER PEDAL 6M100 SCREW 8 - 12 LOCTITE SILENCER PROTECTOR 4M70 SCREW 1 - 2 LOCTITE HANDLEBAR COUNTERWEIGHT SCREW 4 - 5 LOCTITE ENGINE 10M150 SCREW 35 - 40 FRONT / REAR DISC BRAKES 8M125 SCREW 17 - 19 LOCTITE SUSPENSION LINK / SWINGING ARM LINKAGE

SCREW 38 - 40

ENGINE / BANANA ARM 10M150 SCREW 20 - 25 LOCTITE

TORQUE SETTINGS

Disassemble fork legs

- Withdraw 4 mudguard screws and remove the mudguard.

- Slacken off the wheel shaft, withdraw the washer, loosen the 2 front brake caliper screws, loosen the locking nut, withdraw the wheel shaft, the wheel spacer piece and leave the transfer box hanging loose.

Left hand fork leg

- In order to be able to disassemble the left hand fork leg without removing the forks, the following steps should be followed:

- Remove the mudguard and withdraw the locking ring.

- Withdraw the 2 bag carrier screws.

- Withdraw the 7 inner front shield screws and remove the inner front shield.

- Slacken off the 6 x 100 nut and washer, and then we can withdraw the left hand fork leg, which is a hydraulic cartridge complete with the bushing and silentbloc, the boss, rubber stop spring and guide washer.

If the cartridge is losing oil, it must be replaced

because it cannot be repaired.

Right hand fork leg

- Extract the dustguard and the locking ring.

- Withdraw the right hand fork leg, the lower spring washer, the rubber stop and the spring.

This fork leg is filled only with AGIP GR MU 3 type grease.

Re-assembly of the fork legs is carried out in the reverse order to disassembly.

FRONT FORKS

For all ATLANTIS models, hydraulic Kayaba is incorporated.

Disassemble fork legs

- Withdraw 4 mudguard screws and remove the mudguard.

- Slacken off the plate lock screw and withdraw the hand fork leg assembly.

- Do the same with the other hand fork leg.

- Now, we can substitute any front fork element, or we simply can change the hydraulic oil of it.

Front fork route.....................................65 mm.

Hand fork leg diameter.........................26 mm.

Oil capacity for each hand fork leg.......47 cc

Oil type .................................................Agip FORK

SAE 7,5 W

Re-assembly of the fork legs is carried out in the reverse order to disassembly.

KAYABA FRONT FORKS

PREDATOR LC:

Progressive hydraulic shock absorber with linkage

Length of shock absorber...........................300 mm

Shock absorber travel..................................80 mm

Length of spring .........................................228 mm

Spring compression.....................kc = 1.8 kgf / mm

Stud..............................................................10 mm

Maintenance of the shock absorber swinging arm

- The part should be kept cleaned and well-greased.

- If the swinging arm seizes up, check the bushing and the swinging arm linkage seals.

- When fitting the bushing and the swinging arm seals, they should be well-greased using lithium grease.

- The torque setting for tightening up the shock absorber swinging arm and main linkage assembly screws and nuts is 38 - 40 Nw x m

PREDATOR O

Hydraulic shock absorber

Length of shock absorber...........................297 mm

Shock absorber travel..................................65 mm

Length of spring .........................................237 mm

Spring compression force to 20.5 mm.......43 kg.m.

Spring compression force to 65 mm........259 kg.m.

Stud..............................................................10 mm

If the shock absorber is losing hydraulic fluid, it should be replaced.

REAR SUSPENSION

ATLANTIS LC:

- Hydraulic shock absorber / with spring regulation.

Length of shock absorber...........................245 mm

Shock absorber travel..................................60 mm

Length of spring .........................................191 mm

Length of spring LC....................................171 mm

Spring compression force to 30 mm........142 kg.m.

Spring compression force to 60 mm........282 kg.m.

Stud..............................................................10 mm

ATLANTIS 100:

- Hydraulic shock absorber with spring regulation for one or two passengers.

Length of shock absorber...........................290 mm

Shock absorber travel..................................60 mm

Length of spring .........................................218 mm

Spring compression force to 30 mm........142 kg.m.

Spring compression force to 60 mm........282 kg.m.

Stud..............................................................10 mm

PREDATOR LC

- Remove the antifreeze liquid drain plug.

- Withdraw the engine inspection cover securing screw.

- Disconnect the thermo-contact.

- Withdraw the cylinder-head water outlet hose connector and clip.

- Disconnect the throttle cable at the connector.

- Disconnect the crankcase coolant hose and clip at the connection to the crankscase.

- Withdraw the high tension coil securing screw and coil earth.

- Disconnect the oil hose at the connector.

- Withdraw the 2 (fuel and vacuum) hoses from the fuel cock.

- Extract the 2 rear brake caliper screws and leave the caliper lying on the engine.

- Remove the engine earth cable screw.

- Disconnect the electrical connectors to the magneto, cut-off, starter and automatic choke.

- Withdraw the 2 engine frame anchorage securing screws.

- Withdraw the suspension link screw.

- Remove the engine from the frame.

PREDATOR O

2 / ATLANTIS O2

ATLANTIS LC / ATLANTIS 100

- Remove the throttle cable from the connector.

- Withdraw the screw and the low seat body (Atlantis).

- Withdraw the screw and the engine record cover (Predator).

- Withdraw the high tension coil securing screw and coil earth.

- Disconnect the oil hose at the connector.

- Withdraw the 2 (fuel and vacuum) hoses from the fuel cock.

- Withdraw the rear brake cable guide screw.

- Withdraw the rear brake nut.

- Remove the engine earth cable screw.

- Remove the carburettor access cover and withdraw the manual choke cable.

- Disconnect the electrical connectors to the magneto, cut-off, and starter.

- Withdraw the 2 engine frame anchorage securing screws.

- Withdraw the lower rear shock absorber screw.

- Remove the engine from the frame.

- Remove the antifreeze liquid drain plug (Atlantis LC).

- Disconnect the thermo-contact (Atlantis LC).

- Withdraw the cylinder-head water outlet hose connector and clip (Atlantis LC).

- Withdraw the coolant hose at the connection to the radiator (Atlantis LC).

REMOVING THE ENGINE FROM THE FRAME

CHECKING THE IGNITION Inspecting the magneto

- Pull out the connector block which is located at the rear left hand side of the frame.

- Disconnect the magneto cables.

The red/black high tension coil feeder cable and the 2-way connector with red/white and white/yellow cables.

- Check the resistance readings as per the following table:

KOKUSAN DENKI

Black / red White / red White / yellow

Earth

224 Ω 0.70 Ω 0.55 Ω ± 20% ± 20% ± 20%

IDM

Black / red White / red White / yellow

Earth

298 Ω 1.7 Ω 1.5 Ω ± 20% ± 20% ± 20%

- The readings for this table should be taken between 20º and 30ºC. If the values prescribed in the tables are not met, check the wiring before replacing the magneto.

High Tension Coil

- The resistance of the secondary winding of the high tension coil should read from 5 to 6 KΩ.

Spark plug cap

- The resistance between the terminals for the spark plug cap should read from 4 to 5 KΩ.

MAGNETO

LEONELLI

Green

Red / White White

/ yellow

Earth

540 Ω 1,8 Ω 2 Ω

± 15% ± 15% ± 15%

Table of Cylinder and Piston tolerances

PREDATOR - ATLANTIS ATLANTIS 100

LC – O

2 – CAT – WVTA O2 – WVTA

PISTON RINGS Checking:

- Fit the rings into the cylinder.

- Using feeler gauges, measure the play at the ends of the rings.

The maximum value should be 0.5 mm

Fitting the piston rings onto the piston

- Fit the expansion ring.

- Then fit the lower ring - "this has a rectangular section", and finally the upper piston ring - "this has a trapezoidal section".

PISTON Checking:

- Measure the outside diameter of the piston at a point situated 15 mm from the base of the piston.

- Calculate the play between the cylinder and the piston.

- The service limit is 0.06 mm

- When replacing the piston with a new one, take care to use one with the same family identification letter. This letter may be found marked on the upper surfaces of the piston and of the cylinder.

C = FAMILY 09 = MONTH WHEN MANUFACTURED 98 = YEAR WHEN MANUFACTURED

3 = OPERATIVE

CYLINDER HEAD, CYLINDER AND PISTON

FAMILY PISTON CYLINDER PLAY

ASSO SP348

A 40,95

+ 0,004

40,975

+0,005

- 0 - 0

B 40,955

+0,004

40,980

+0,005

- 0 - 0

C 40,960

+0,004

40,985

+0,005

- 0 - 0

D 40,965

+0,004

40,990

+0,005

- 0 - 0

From

0,021

0,030

FAMILY CYLINDER PLAY

From

PISTON

ASSO

49,966

± 0,0025

50,0075

± 0,0025

49,971

± 0,0025

50,0125

± 0,0025

49,976

± 0,0025

50,0175

± 0,0025

49,981

± 0,0025

50,0225

± 0,0025

0,0365

0,0455

Atlantis 100 with

semitrapezoidal rings

and without

expander ring.

CYLINDER HEAD Compression Ratio: 11.5:1

Compression Ratio ATLANTIS 100: 9.5:1

PREDATOR LC / O2

- The gaskets should be replaced every time the cylinder head is removed.- Check that the cylinder head is gas-tight. There should be no more than 0.05 mm gap.

Cylinder head torque settings: 10 - 12 Nw x m. Cylinder head torque settings

ATLANTIS 100: 18 - 20 Nw x m.

PREDATOR LC Thermostat

Starts to open at 55º ± 2 ºC Length of travel 3.5 mm 60º ± 2 ºC

Thermoresistance

For temperature gauges with needle

Temperature º C Resistance ± 10 % Ω

25 788 80 98

Thermocontact

For models with electrical fan

Make contact at 97 ± 3 ºC Break contact at 85 ± 3 ºC

Cooling system

Coolant antifreeze:

AGIP CLOSED SYSTEM PLUS 30%

Cooling system capacity Predator LC......825 c.c.

Cooling system capacity Atlantis LC........400 c.c.

Pressure in cooling system......................1.2 ± 1º

Spark plugs

PREDATOR O2 NGK B 8 HS / CHAMPION L 78 C ATLANTIS NGK B 8 HS / CHAMPION L 78 C PREDATOR L.C. NGK B 9 ES / CHAMPION N 2 C ATLANTIS L.C. NGK B 9 ES / CHAMPION N 2 C ATLANTIS 100 NGK B 9 ES / CHAMPION N 2 C PREDATOR L.C. (CAT) NGK B 8 ES / CHAMPION N 3 C

DRIVE:

Trapezoidal belt

The width of the belt in optimum condition should be 16.5 mm The limit for wear in the trapezoidal belt is either 0.5 mm or 10,000 km.

Clutch shoes The service limit of the shoes is 2 mm.

Clutch hub

The service limit on the clutch hub is 112.5 mm. The service limit on the clutch hub is 110,5 mm. (ATLANTIS O

2 / LC)

Inspection of the clutch pulley:

In the event that the fixed pulley of the clutch is disassembled, it should be cleaned and greased using lithium grease of the following specification: 250 ºC ASTM D 217

Working temperature +160º C / -25º C using a quantity of 3 to 3.5 grams.

Torque setting - clutch nut: 65-70 Nw x m Torque setting - pulley shaft nut: 35-40 Nw x m (using loctite) Torque setting - variable speed unit nut: 35-40 Nw x m (using loctite)

CRANKSHAFT

PREDATOR / ATLANTIS ATLANTIS 100

Lateral play at conncting rod big end

Maximum axial play 0.700 mm. Maximum axial play 0.630 mm.

Minimum axial play 0.330 mm. Minimum axial play 0.250 mm

Crankshaft counterweight 39 - 0.3 mm. 43 - 0.2 mm. inspection and verification - 0.4 mm. - 0.3 mm.

Inspection of radial play at bearing surfaces

0.04 mm. (both sides)

0.04 mm.

(both sides)

Lateral play in crankshaft 0.84 mm. (max. Axial)

Maximum axial play 0.74 mm.

Minimum axial play 0.20 mm.

Koyo: 83299 - 9RTCS31 Koyo: 83299 – 9RTCS31

Crankshaft bearings NTN: 6204 px2v4 NTN: 6204 px2v4

Nachi: 20BC05S16 Nachi: 20BC05S16

MODEL BELT ROLLERS ROLLERS CAT - WVTA CLUTCH SHOES SPRING REDUCTION

PREDATOR 836 (mm) 6,15x6=37 (gr) 8,33x6= 50 (gr) 112 (mm) 543 (mm) 29,5 Kg a 41 mm. 12/43X14/48

ATLANTIS 836 (mm) 5,90X6=35,5 (gr) 7,66X6= 46 (gr) 110 (mm) 525 (mm) 30,6 Kg a 45,5 mm. 12/43X14/48

ATLANTIS 100 850 (mm) 10,66X6=64 (gr) 10,66X6= 64 (gr) 112 (mm) 543 (mm) 29,5 Kg a 43,5 mm. 12/43X15/40

VARIADOR REDUCTOR

CARBURETTORS

- In PREDATOR LC models there is an automatic choke.

- In PREDATOR O2, ATLANTIS and ATLANTIS LC models the choke is manually operated.

- Maintenance and cleaning of the carburettor are extremely important for the correct performance of the scooter.

- Cleaning and maintenance of the filter box are also vital to keep fuel consumption within normal limits.

- Inspection of the float needle: inspect the float needle for wear: a worn needle may cause damage to the engine.

BRAND CARBURETOR MODELS

JET

MAIN

JET

IDLE AIR STARTER FLOAT

NEEDLE

POSITION EMULSIFIER

SCREW JET LEVEL

WEBER 14 OM 1BA PREDATOR LC (E) 66 AB – 3ª 38/35 G8 2 Turns 55 16,5 ± 1 WEBER 14 OM 1FA PREDATOR O2 (E) 66 AB – 3ª 38/35 G8 2 Turns 55 16,5 ± 1 WEBER 12 OM 1QA PREDATOR LC (I) 66 G – 2ªª 35/35 G8 2 Turns 55 16,5 ± 1 WEBER 12 OM 1SA PREDATOR O2 (I) 66 G – 2ªª 35/35 G8 2 Turns 55 16,5 ± 1 DELL ’ ORTO PHVA 14 DD PREDATOR LC (E) 57 A 11 – 3º 34 210 GA 1

3/4

Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 14 DD PREDATOR O2 (E) 57 A 11 – 3º 34 210 GA 1

3/4

Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 12 DD PREDATOR LC (I) 57 A 11 – 3º 34 212 GA 1

3/4

Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 12 DD PREDATOR O2 (I) 57 A 11 – 3º 34 212 GA 1

3/4

Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 12 DD

PREDATOR LC (I) CAT

49 A 11 – 3º 32 212 GA 1

3/4

Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 12 DD

PREDATOR O2 (I) CAT

49 A 11 – 3º 32 212 GA 1

3/4

Turns 50 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD PREDATOR LC (A) 50 A 11 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD PREDATOR O2 (A) 50 A 11 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD

PREDATOR LC WVTA

50 A 14 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 14 DD

PREDATOR O2WVTA

50 A 14 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5 WEBER 12 OM 1SA ATLANTIS (I) 66 G – 2ªª 35/35 G8 2 Turns 55 16,5 ± 1 DELL ’ ORTO PHVA 14 DD ATLANTIS (E) 57 A 11 – 3º 34 210 GA 1

3/4

Turns 50 14,3 ± 0,5

DELL ’ ORTO PHVA 14 DD ATLANTIS (F) 57 A 11 – 3º 34 210 GA 1

3/4

Turns 50 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD ATLANTIS WVTA 50 A 14 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD ATLANTIS LC (E) 57 A 11 – 3º 34 210 GA 1

3/4

Turns 50 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD

ATLANTIS LC (I) CAT

50 A 14 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 14 DD ATLANTIS LC (F) 57 A 11 – 3º 34 210 GA 1

3/4

Turns 50 14,3 ± 0,5 DELL ’ ORTO PHVA 14 DD

ATLANTIS LC WVTA

50 A 14 –4º 34 211 GA 2 Turns 45 14,3 ± 0,5

DELL ’ ORTO PHVA 17,5 DD

ATLANTIS 100 WVTA

69 A 21 – 3º 36 210 GA 2 Turns 50 14,3 ± 0,5

DELL ’ ORTO PHVA 14 DD

ATLANTIS 30 Km H.

50 A 14 – 4º 34 211 GA 2 Turns 45 14,3 ± 0,5

Adjustment Table

GENERAL CHARACTERISTICS

Component Standard values Battery:

Type 12V 4 Ah Special electrolyte. Maintenance free Specific gravity 1,32 at 20º C.

Battery charging system:

Type Alternator and regulator Voltage under load 13,5 ± 0,5 V at 4.000 r.p.m. with lights on Coil resistance 1,1 ± 0,2 Ω at 20º C.

Lighting system:

Type Alternator and regulator Regulation voltage 13,5 ± 0,5 V at 4.000 r.p.m. with lights on Coil resistance 0,9 ± 0,2 Ω at 20º C.

Ignition system:

Type Electronic

Magneto:

Resistance of stator between Black/Red cables and earth 224 Ω±20% a 20º C.

High Tension Coil:

Resistance of secondary winding 5 ± 1 KΩ Resistance of anti-interference cap 4 ± 1 KΩ

Switches and Sensors:

Brake light switches Light operates after 12 mm. travel at

brake levers

Fuel sensor Full: ∞Ω/ Reserve: 33 Ω Oil sensor Full: ∞Ω/ Reserve: 0 Ω Temperature thermo-resistance 25 ºC 788 Ω±10%

80 ºC 98 Ω±10%

Cooling fan thermo-contact OFF-ON 97 ± 3 ºC

ON-OFF 85 ± 3 ºC

ELECTRICAL SYSTEM

BATTERY

- When the battery is used for the first time, it is necessary to fill with the acid which comes together with the battery.

- First remove the sealing strip.

- Next place the container of electrolyte upside down with the six sealed parts aligned with the six filler holes on the battery. Push the container firmly down to break the seals.

- Check that all the electrolyte has gone into the battery.

Sealing up the battery:

- Push the sealing strip firmly into each of the filler holes.

- Never remove the sealing strip, and never add water to the electrolyte.

- The battery is a 12V 4 Ah type. When installing the battery it is important not to reverse the polarity of the terminals, since this could cause damage to some sensitive electronic components.

Using the battery for the first time:

- This battery is a sealed type and the cell covers should never be removed, and water must never be added.

- After 30 minutes test the voltage at the terminals.

Standard voltage 12.5 volts minimum

Under normal circumstances it is not necessary to charge the battery. Once charged it is normally at 75% capacity.

Special conditions under which the battery

should be charged:

- When the temperature falls below 0 ºC.

- After a long period in storage.

- When the original seal has been broken.

- In general the battery should be charged whenever the voltage after charging remains below the standard reading of 12.5 V.

CHECKING THE ELECTRICAL SYSTEM IN THE SCOOTER

STARTER RELAY

- Check the resistance between each of the terminals.

- Resistance between 85 and 86 = 55 Ω±15%.

- In order to measure continuity between the contacts, connect poles 85 and 86 to the battery and pole 30 and 87 to the tester: the result of this test should be a reading of 0 ohms (closed circuit). When poles 85 and 86 are disconnected from the battery, the tester should read infinity, or open circuit.

- If there is any variation from these readings, the relay should be replaced.

THERMOCONTACT

FUSE 4 AMP

4AMP

R/BL

IGNITION SWITCH

BATTERY

R/BL RED/ BLACK + FROM IGNITION SWITCH WH WHITE + FROM FAN

FAN

CHARGING SYSTEM:

- It is necessary to use a charger with constant voltage and current.

Standard charge: 0.3 Ah for 10 hours if the

voltage is below 12.5 volts.

- Carry out battery charging in accordance with the accompanying table.

11,5 12,0 12,5 13,0 V

Voltage at the battery terminals

Charging time

Standard values for determining the condition of the battery

Voltage is 12.5 or higher Correct Voltage between 12.0 - 12.4

Insufficient charge (recharge battery)

Voltage at 11.9 or less Unserviceable

(replace battery)

Control diagram to determine

battery state

Standard battery charging times

85 86

WIRING DIAGRAM AND CONTROL OF THE FAN CIRCUIT

13,0

12,5

12,0

11,5

Voltage at the terminals (V)

0 255075

Battery Charge (%)

Recharging necessary Battery Charged

100

ECHEMA ELECTRIQUE PREDATOR

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE PREDATOR O

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE ATLANTIS

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE ATLANTIS LC

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE ATLANTIS (USA)

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE PREDATOR (USA)

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

ECHEMA ELECTRIQUE ATLANTIS 100

Orange Grün Schwarz Braun WeiB Grau Gelb Blau Rot Rosa Violett

Orange Vert Noir Marron Blanc Gris Jaune Blau Rouge Rosa Violet

Orange Green Black Brown White Gray Yellow Blue Red Pink Violet

Arancio Verde Nero Marrone Bianco Grigio Giallo Azzurro Rosso Rosa Viola

Naranja Verde Negro Marron Blanco Gris Amarillo Azul Rojo Rosa Violeta

G Y

R P

DFUKIE

WORKSHOP MANUAL

GP 1

GP SERIES

ATLANTIS

* 50 C.C. ENGINE PIAGGIO

SPECIAL TOOLS

Description Reference

1 - Bearing extractor..............................................................................................004499Y

2 - Heat gun...........................................................................................................020151Y

3 - Needle bearing punch......................................................................................020080Y

4 - Magneto extractor............................................................................................020162Y

5 - Heat gun holder................................................................................................020150Y

6 - Crankcase separator........................................................................................020163Y

7 - Semi-pulley assembly sleeve...........................................................................020164Y

8 - Water-pump impeller retaining tool..................................................................020167Y

9 - Starter crown wheel retaining tool....................................................................020165Y

10 - Crankcase-half water-seal assembly punch....................................................020168Y

SPECIAL TOOLS

Description Reference

11 - Spring clip assembly tool .................................................................................020166Y

12 - Water-pump drive shaft (dis)assembly wrench................................................020169Y

13 - Mixer drive gear extractor tool..........................................................................020361Y

14 - Starter spring assembly tool.............................................................................020261Y

15 - Comparator and holder....................................................................................020335Y

16 - Crankshaft support...........................................................................................020163Y

17 - Crankshaft seal punch.....................................................................................020340Y

18 - Valve separation tool........................................................................................020341Y

19 - Piston ring assembly tool.................................................................................020344Y

SPECIAL TOOLS

Description Reference

20 - Compressor crankshaft pulley retaining tool....................................................020342Y

21 - Magneto retaining tool......................................................................................020346Y

22 - Starter crown wheel retainer............................................................................020343Y

23 - Crown wheel retainer.......................................................................................020565Y

24 - Engine support.................................................................................................005095Y

25 - Extractor tool....................................................................................................001467Y

Km 1000 2500 5000 10000 15000 20000 25000

Months 2 6 12 24 36

Reduction gear or crankcase oil Replace Check Check Replace Check Replace Check Check cylinder air Clean Suspensions Check Check Check Check Check Tighten fastenings Check Check Check Check Check Check Check Electrical Connections Check Check Check Check Check Check Check Spark plug Clean Adjust Replace Replace Replace Replace Replace Battery Check Check Check Check Check Check Carburettor

Adjust / Clean Adjust / Clean Adjust / Clean Adjust / Clean Adjust / Clean Adjust / Clean Adjust / Clean

Oil pump / Fuel valve Adjust Adjust Adjust Adjust Adjust Adjust Adjust Variable speed rollers /

Transmission belt Check

Replace Oil Filter Check Replace Check Replace Check Air Filter Clean Clean Clean Clean Clean Secondary Air Filter Clean Clean Clean Clean Clean Brakes / Pads Check Check Check Check Check Brake equipment Check Check Brake fluid EVERY 2 YEARS EVERY 2 YEARS Tyres Check Check Check Check Check Tyre pressures Check Check Check Check Check Check Check Fuel or oil hoses Check Replace Check Replace Check Transmission Lubricate Lubricate Lubricate Lubricate Lubricate Starter gears to pedal Clean Clean Clean Clean Clean

and grease and grease and grease and grease and grease

REGULAR MAINTENANCE CHART

GP1 - GP Series O2- ATLANTIS

Period: this period can be calculated by kilometres run or by time in months

DESCRIPTION TORQUE SETTING

Nw x m

CALIPER ROTATION SHAFT 8M125 17 - 19 LOCTITE CYLINDER STUD 6M100 STUD 10 - 12 CRANKCASE HALVES JOINT 6M100 SCREW 12 - 13 CYLINDER HEAD 6M100 NUT 10 - 11 INLET MANIFOLD VALVE SUPPORT SCREW 1 - 2 LOCTITE CRANKCASE INLET MANIFOLD SCREW 9 - 10 LOCTITE OIL PUMP 5M80 SCREW 3 - 4 COIL TO BASE PLATE SCREW 8 - 10 BASE PLATE TO CRANKCASE SCREW 8 - 10 MAGNETO NUT 40 - 44 LOCTITE PICK-UP SCREW SCREW 4 - 5 STARTER MOTOR 6M100 SCREW 12 - 13 FAN TO MAGNETO SCREW 3 - 4 LEFT-HAND CRANKCASE HALF NUT 40 - 44 REDUCTION GEAR COVER 6M100 SCREW 12 - 13 PULLEY SHAFT NUT 40 - 44 LOCTITE CLUTCH NUT 50 - 60 PLASTIC OIL FILLER CAP CAP 3 - 5 LEFT-HAND CRANKCASE COVER 6M100 SCREW 12 - 13 OIL DRAIN PLUG 8M125 SCREW 17 - 19 CYLINDER SLEEVE COVER 6M100 SCREW 4 - 5 FRONT WHEEL 12M150 NUT 35 - 50 REAR RIM SECURING NUT NUT 17 - 19 HUB TO REAR WHEEL AXLE 16M150 NUT 115 - 125 ENGINE SUPPORT TO FRAME 10M150 NUT 30 - 40 SHOCK ABSORBER UP/ DOWN 10M150 NUT 30 - 40 HANDLEBAR 8M125 SCREW 15 - 19 EXHAUST PIPE TO CYLINDER 6M100 SCREW 9 - 12 EXHAUST PIPE TO CRANKCASE 10M150 SCREW 15 - 19 FORK LEG SECURING NUT 6M100 NUT 8 - 10 STEERING 25M100 NUT 90 - 130 FRONT BRAKE CALIPER 8M125 SCREW 17 - 19 BRAKE CALIPER TO CRANKCASE 8M125 SCREW 17 - 19 STARTER PEDAL 6M100 SCREW 8 - 12 SILENCER PROTECTOR 4M70 SCREW 1 - 2 LOCTITE HANDLEBAR COUNTERWEIGHT SCREW 4 - 5 LOCTITE ENGINE TO SUPPORT 10M150 SCREW 30 - 40 BRAKE DISC FRONT / REAR 8M125 SCREW 17 - 19 LOCTITE CENTRE STAND TO CRANKCASE SCREW 17 - 19

TORQUE SETTINGS

FOR PROPER MAINTENANCE AND REPAIR OF THE PAIOLI FORKS, IT IS RECOMMENDED THAT THEY SHOULD BE REMOVED FROM THE FRAME.

TO REMOVE THE FORKS FROM THE FRAME:

- Remove the fairing.

- Loosen off the screws in the upper casing.

- Disconnect the connections in the instrument panel, Speedometer sleeve, instrument connectors, grip lighting switch connectors, stop light, indicators, and cut the rear brake clip,

- Remove upper casing.

- Remove the shield backing plate.

- Loosen and remove the 2 handlebar screws.

- Loosen the front forks nut.

- Loosen and remove the 4 mudguard screws.

- Loosen the wheel shaft nut, remove the washer,

- Loosen the 2 front brake caliper screws.

- Loosen the locking screw, remove the wheel shaft,the wheel spacer, and leave the speedometer cable hanging free.

- Remove the forks.

STRIPPING THE LEFT / RIGHT FORK LEG

PAIOLI FRONT FORKS

Suspension stroke ........................... 80 mm.

Diameter of fork bars........................32 mm.

Oil capacity in each bar....................100 C.C.

Type of oil.........................................Agip FORK

SAE 7,5 W

REAR SUSPENSION: GP 1 - GP SERIES

Hydraulic shock absorber

Length of shock absorber.................297 mm.

Shock absorber stroke .....................64 mm.

Length of spring................................235 mm.

Spring compression at 36 mm.........127 kg.m

Spring compression at 64 mm.........254 kg.m

Stud..................................................10 mm.

ENGINE

- Place the complete engine on the special stand. take extreme care when working

with petrol

when installing the battery, connect the positive cable first, and then the negative cable.

The use of protective glasses is

recommended when using percussion tools.

Tool: 19.1.25095

Warning !!!

Caution!

÷ ÷

LUBRICATE

GREASE

APPLY THE PRODUCT

CLEAN WITH CARE

CAUTION HANDLE WITH CARE

ALWAYS REPLACE

SYMBOL

QUANTITY

TORQUE N.M.

MAGNETO

Starter motor

- The securing nuts are the one indicated in the drawing and the one diametrically opposite.

Flying cover

- Remove the four screws covers steering wheel.

- Models cooled by liquid.

Fan Cover

- Remove the four screws and disengage the two lugs inserted in the cylinder cooling jacket.

- If the vehicle is used for off-road duty, it is advisable to remove the outer part of the cover and clean the silencer element with compressed air and/or water.

Magneto

Extractor: 19.1.20162

Magneto securing nut

- During this operation, secure the magneto using the special tool for this purpose.

Special tool: 19.1.20565

Stator pick-up

N.B. Assemble the parts by following the

stripping procedure in reverse.

- Use a new nut to ensure proper adjustment.

N.B. It is good practice after assembling the mag-

neto to protect the extractor tool screw with Agip GR MU 3 grease.

Magneto nut torque setting 40 ± 4 N x m.

All operations to check the wiring which involve disconnecting cables (checking connections and devices which form part of the ignition circuit) must

be performed with the engine switched off:

otherwise the central unit may suffer irreparable damage.

These checks should be performed if the ignition is irregular, or if there is no spark at the spark plug.

1)Check the spark plug (clean with wire brush, remove soot, blow clean with compressed air, if necessary replace).

2) Without stripping the stator, perform the following check:

After visual examination of the electrical connections, measure the characteristics of the coil and the pick-up (see table).

If any anomalies appear when checking the coil and the pick-up, replace the stator and the damaged parts.

Remember that in order to replace the central unit, cables must only be disconnected with the engine switched off.

ELECTRONIC IGNITION

White

Fig. 2

Fig. 3

Fig. 1

Red

White Green

CHECKING THE PICK-UP (Fig. 2)

Instrument connected between:

Value (Ω)

1) Red and White Cables 90 ± 140 Ω

CHECKING THE Coil (Fig. 3)

Instrument connected between:

Value (Ω)

1) White and Green Cables

800 ± 1100 Ω

CHECKING for Continuity

Instrument connected between:

Value (Ω)

1) White Cable and Frame Continuity

2) White Cable and Engine Continuity

TRANSMISSION - MIXER

÷ ÷

LUBRICATE

GREASE

APPLY THE PRODUCT

CLEAN WITH CARE

CAUTION HANDLE WITH CARE

ALWAYS REPLACE

SYMBOL

QUANTITY

TORQUE N.M.

Transmission Cover

- Unscrew the 15 screws, and remove the transmission cover using a raw-hide hammer.

N.B. the crankcase remains lightly secured by the

driven semi-pulley shaft in the bushing fitted into the crankcase itself.

Follower Pulley

- Remove the nut.

- Withdraw the complete unit.

Special tool: 19.1.20165

Starter gearing – Drive pulley

Special tool: 19.1.20165

Controls Drive belt

- Verify that the drive belt is not deteriorated

- Control the width of the drive belt

Minimum permissible 17,5 mm.

N.B. to control the drive belt and the container of

rollers each 20,000 km

Belt - Starter cable - Variable speed unit Mixer

Movil semi pulley

- Remove the three screws and the cover.

Variable speed plate

- Remove the O-ring and the variable speed plate.

Rollers

- Withdraw the rollers. Lift out the rollers, marking them with a felt pen to ensure correct reassembly.

Rollers

- Check that the rollers are not damaged or worn.

Limit of wear 18.5 mm minimum diameter.

Transmission - mixer variable speed unit

- Check that the interior bushing shows no sign of unusual wear and measure the interior diameter.

Maximum permitted diameter 20.12 mm max.

N.B. Do not lubricate or clean the anti-friction

bushing.

Pulley displacement bush

- Measure the external diameter of the sliding pulley bush.

Minimum permissible diameter 19.95 mm

Variable Speed unit roller ramps

- Grease the working surfaces of the rollers using Agip GR MU 3 grease, and re-assemble the rollers.

N.B. For correct assembly, if the rollers are not

being replaced, re-fit them into their original seatings.

Variador guide

- Assemble the roller cover, the oil plate, and the cover, securing with the three screws.

- Assemble the roller backing plate, the oil seal, and the cover, securing with the three screws.

Follower Pulley

- Check that the clutch casing is not worn or damaged.

- Measure the internal diameter of the clutch casing. Maximum diameter value 107.5 mm.

N.B. Mount it on the appropriate shaft and check

for eccentricity: maximum value 0.20 mm.

Clutch

- Remove the central nut while holding the pulley rigid using the special tool.

During the stripping operation on the clutch unit securing nut, take care to keep the unit itself in its housing; it may be ejected by the force of the clutch spring.

Special tool: 19.1.20565

Stud retaining collar

- Withdraw the retaining collar.

Guide roller studs

- Extract the guide roller studs, and withdraw the mobile follower semi-pulley from the fixed follower semi-pulley.

Fixed follower semi-pulley

- Measure the external diameter of the pulley bush.

Minimum permissible diameter 33.96 mm.

Mobile follower semi-pulley

- Measure the internal diameter of the moving semi-pulley bush.

Maximum wear limit 34.08 mm.

Caution!

Spring

- Measure the length of the moving follower semipulley spring.

Minimum permissible length limit 110 mm.

Fixed follower semi-pulley bushing

- Extract the old bushings and insert new replacements, using a piece of tubing of the right diameter as a punch.

Checking the Clutch

- The clutch assembly should be replaced when the joint is less than 1 mm at its thinnest part.

- This assembly should be replaced as a complete unit, because it is balanced after assembly of the clutch weights.

Re-assembly of the semi-pulley

- Insert the mobile semi-pulley into the fixed semipulley using the protective sleeve, after replacing the sealing rings and the O-rings, fit the studs with their respective rollers using a small quantity of Agip GR MU 3 grease.

- After completing this operation it is necessary to apply, using a curved point syringe, a sufficient quantity of grease such that when it is injected through one of the holes situated in the interior of the bushing, it squeezes out of the opposite hole.

Special tool: 19.1.20164

Re-assembly of the clutch

- Refit the stud retaining collar, the spring, the clutch assembly, and lock the clutch nut.

During the stripping operation on the clutch unit securing nut, take care to keep the unit itself in its housing; it may be ejected by the force of the clutch spring.

Special tool: 19.1.20565 Torque setting: 40 ÷ 44 N x m Loctite 242 Nut sealing paste

Mixer drive gear and belt

- Withdraw the gear and the belt. Do not twist or fold the belt during

assembly.

During assembly, carefully lubricate

the mixer drive stud and bush, using only CONSTANT GLY 21000 oil, and make sure that it is free to move.

N.B. Replace the belt every 20,000 kilometres.

Follower pulley, clutch, belt

- Assemble the follower pulley - clutch - belt

assembly.

Clutch hub

- Assemble the clutch hub and tighten the nut while

holding the hub itself rigid by means of the special tool.

N.B. On assembly, use new nuts and apply

Loctite “Super Fast” type 242 E.

Special tool 19.1.20565 Torque setting 40 ÷ 44 N x m

Caution!

Bushing and mobile semi-pulley

- Fit the assembly while taking care not to damage the transmission belt.

- It is essential to open out the rear pulley in order to fit the belt. It is vitally important when tightening the front pulley assembly to ensure that the belt is free to move inside it, otherwise the semipulley may not be tightened correctly.

Mixer - Starter cable - Belt Fixed semi-pulley

- Handle with care so as to avoid twisting the belt.

Fan - Fan securing disc - Washer - Nut

- Apply recommended thread sealer

use only nuts supplied as original

spare parts.

N.B. When assembling use new nuts in order to

ensure correct engagement.

Torque setting: 40 ÷ 44 N x m Special tool: 19.1.20165 Loctite 242 E

Reduction gear cover

- Before carrying out this operation, drain the oil from the reduction gear by means of the drain plug.

Caution!

Follower pulley shaft oil seal

- Strip the oil seal.

Reduction gear cover bearings

- After removing the Seeger ring, withdraw the bearing.

- When stripping the wheel shaft bearing, use the special tool.

Special tool: 12.1.21467 13/17 for wheel shaft

Reduction gear housing bearing

- Heat the cover using the heat gun on its stand, and fit the bearing, let the cover cool down, and then fit the oil seal and the needle bearing using the appropriate punch. Fit the follower pulley shaft bearing Seeger ring ensuring that it is positioned correctly.

- The concave side of the Seeger ring must face the bearing.

Special tool: 19.1.20151 (heat gun) Special tool: 19.1.20150 (holder) Special tool: 19.1.20080

Assembly of follower pulley shaft

- Assemble the pulley shaft onto the bush cover by tapping lightly with a rawhide hammer.

Reduction gearing

N.B. If necessary when withdrawing the reduction

gearing, use a plastic hammer, tapping lightly on the opposite side to that shown in the figure.

Crankcase bearings

- Wheel shaft bushing:

- Withdraw the oil seal and the Seeger ring, extract the bushing.

- Follower pulley shaft bushing.

- Use the special tool.

N.B. Perform the same operations on the bea-

rings in the crankcase cover.

Extractor tool 19.1.21467/21/17

Crankcase bearings

- Heat up the crankcase halves to approximately 80ºC, and then assemble the bearings.

Support 19.1.20150 Heat gun 19.1.20151

Crankcase bearings

place the stop washers correctly on

the intermediate shaft.

Caution!

Mating the crankcase halves

- Apply Loctite 510 to the mating surfaces.

- Tighten the screws to the prescribed torque setting.

N.B. Always check that the compensator ring is

correctly in place and well-greased.

Torque settings 12 ÷ 13 N x m

Replacing the starter pedal

- Remove the screw as shown in the figure and withdraw the starter pedal.

- For re-assembly follow the same operation in reverse, and tighten to the specified torque setting.

Torque setting: 12-13 N·m

Replacement of the toothed segment and starter-crankshaft gearing

- Remove the Seeger ring situated on the outside of the crankcase.

- Strip the starter gearing from its housing, relaxing the pressure exerted by the toothed segment through the spring; in order to do this, it is necessary to rotate the toothed segment slightly (see figure).

During the stripping operation on the toothed segment, take extreme care over the tension exerted by the spring: this could injure the operator.

Assembling the toothed segment and starter gearing into the crankcase

- When assembling, apply Agip GR MU to the bush, to the spring, and along the toothed segment.

- To load the spring, use the special tool as shown in the figure.

- Fit the Seeger ring after checking that it is in perfect condition.

Special tool: 19.1.20261

Replacing the reduction gear cover bearing

- In order to replace the bearing in the reduction gear cover, heat up the crankcase and extract the bearing by tapping with gentle blows from a rawhide hammer.

Special tool: 19.1.20150 Special tool: 19.1.20151

Caution!

CYLINDER HEAD - CYLINDER - PISTON

LUBRICATE

GREASE

APPLY THE PRODUCT

CLEAN WITH CARE

CAUTION HANDLE WITH CARE

ALWAYS REPLACE

SYMBOL

QUANTITY

TORQUE N.M.

÷ ÷

Liquid cooled models

Thermostat - cylinder head - by-pass tube

Detail of the thermostat

Cylinder head - Cylinder

Every time the cylinder head is stripped down, replace the two seals and the cylinder head gasket.

Cylinder

Caution!

Cylinder Checking the thickness of the cylinder base gasket

- Assemble the cylinder without using the cylinder

base gasket.

- Fit a hundredths comparator on special tool

19.1.20268 and bring the needle to zero on a rectified surface.

- Fit the tool to the upper part of the cylinder and

secure it with two nuts to the studs, observing the torque setting of 10-11 N·m, and bring the piston to TDC.

- The thickness of the gasket which is required will

vary according to the value observed.

- For this reason 3 gaskets are supplied in the

following thicknesses:

0.75 mm. – 0.5 mm. – 0.4 mm.

Cylinder head torque setting: 10 ÷ 11 N x m Special tool: 19.1 20268

VALUE OF “A” (mm) Thickness of gasket Reference No.

2,85 ÷ 3,10 0,4 435602 3,10 ÷ 3,25 0,5 289499 3,25 ÷ 3,45 0,75 435603

CRANKCASE HALVES - CRANKSHAFT

LUBRICATE

GREASE

APPLY THE PRODUCT

CLEAN WITH CARE

CAUTION HANDLE WITH CARE

ALWAYS REPLACE

SYMBOL

QUANTITY

TORQUE N.M.

Automatic mixer drive gearing and belt

- Strip the gearing and belt.

- If it is difficult to remove the mixer gearing use the

special tool.

Do not twist the belt

Special tool: 19.1.20170

Drain hole

(Transmission side crankcase half)

N.B. In the event of loss of fluid through the drain

hole, carry out a revision of the pump as shown below.

Replacing the water pump seal in the clutch side crankcase half

- Strip the pick-up and remove the water feed hose

to the pump.

- Fit the special tool in the pick-up securing holes.

when re-assembling the pump feed

water hose, use a new seal.

Special tool 19.1.20167

Unscrew the pump drive shaft and withdraw the unit.

The water pump drive shaft has a left-

hand thread.

Special tool: 19.1.20169

Water pump drive shaft

- Note on spare parts: The shaft is supplied com-

plete as shown in the figure.

Caution!

100

Disassembling the seal

Common tools

- Frame type ABC 3065 / 8

- Extractor type USAG A / 17 -10

When assembling, clean the surface scrupulously

- Lubricate the surface and the seal, and check that the seal is correctly inserted and that the drain hole is not blocked.

Special tool: 19.1.20168

Remove the joint screws

- Remove the eight crankcase half joint securing screws.

Separating the crankcase halves

Special tool: 19.1.20163

Extracting the Crankshaft

Special tool: 19.1.20163

derbi predator LC shop SH Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual