Derbi Rambla 250 User Manual

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WORKSHOP MANUAL

RAMBLA 250

WORKSHOP MANUAL

RAMBLA 250

This workshop manual has been drawn up by NACIONAL MOTOR, S.A.U.. Spa to be used by the workshops of DERBI dealers. This manual is addressed to Derbi service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool c atalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Characteristics

Rules

Safety rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.

CAUTION

USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE STARTING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM PARTS. DO NOT HOLD ANY MECHANICAL OR OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOTER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND EVEN TOXIC.

CARBON MONOXIDE

If you need to keep the engine running in order to carry out any procedure, please ensure that you do

so in an open or very well ventilated area.

Never let the engine run in an enclosed area.

If you do work in an enclosed area, make sure to use a smoke-extraction system.

CAUTION

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

FUEL

CAUTION

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

CAUTION

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN HIGH-TEMPERATURE COMPONENTS

CHAR - 7

Characteristics

The engine and the components of the exhaust system can get very hot and remain hot for some time

even after the engine has been switched off.

Before handling these components, make sure that you are wearing insulating gloves or wait until the

engine and the exhaust system have cooled down.

TRANSMISSION OIL AND USED FORK OIL

CAUTION

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

CAUTION

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN BRAKE FLUID

CAUTION

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

CAUTION

KEEP OUT OF THE REACH OF CHILDREN HYDROGEN GAS AND BATTERY ELECTROLYTE

CAUTION

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

CHAR - 8

Characteristics

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIALIST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

CAUTION

THE BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.

CAUTION

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

BEFORE REMOVING COMPONENTS

•

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

•

Use the special tools designed for this scooter, as required.

REMOVAL OF COMPONENTS

•

Do not loosen and/or tighten screws and nuts using pliers or other tools than the specially

designed wrench.

•

Mark positions on all connection joints (pipes, cables etc.) before separating them, and

identify them with distinctive symbols.

•

Each component needs to be clearly marked in order to be identified during reassembly.

•

Clean and wash the dismantled components carefully using a low-flammability detergent.

CHAR - 9

Characteristics

•

Keep coupled parts together since they have "adjusted" to each other due to normal wear

and tear.

•

Some components must be used together or replaced altogether.

•

Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT. AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS SEAT. DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.

NOTE

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY NEED REPLACING.

•

Use only ORIGINAL Derbi SPARE PARTS.

•

Comply with lubricant and consumables usage guidelines.

•

Lubricate parts (whenever possible) before refitting them.

•

When tightening nuts and screws, start from the ones with the largest section or from the

internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-

plying the tightening torque.

•

Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and

screws with new ones if their tread is damaged.

•

When fitting bearings, make sure to lubricate them well.

•

Check that each component is fitted correctly.

•

After a repair or routine maintenance procedure, carry out pre-ride checks and test the ve-

hicle on private grounds or in an area with low traffic density.

•

Clean all coupling surfaces, oil guard rims and washers before refitting them. Apply a light

layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the

bearings with the brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below as non-compliance with the procedure

so described causes irreparable damage to both the connector and the cable harness: Press the rele-

vant safety hooks, if any.

CAUTION

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

•

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

CHAR - 10

Characteristics

•

In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a

pressurised air jet.

•

Make sure that the cables are correctly linked to the connector's internal terminal ends.

NOTE

THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND.

•

Then fit the two connectors making sure that they couple correctly (if the relevant hooks are

provided, you will hear them "click" into place).

TIGHTENING TORQUE

CAUTION

DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

BRAKE FLUID

CAUTION

DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQUIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM. DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT HAVE BEEN OPEN FOR A PROLONGED TIME. SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE TO FAULTS IN THE HYDRAULIC CIRCUIT. MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT SMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND INSPECTION OPERATIONS. CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN. ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY INTO THE CIRCUIT. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT.

DISC BRAKE

CAUTION

ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS. SOILED PADS MUST BE REMOVED AND REPLACED. A SOILED DISC OR A DISC WITH TRACES OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT. IF THE SCOOTER IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS, OR IF IT IS USED FOR SPORTS APPLICATION, HALVE THE SERVICE INTERVALS.

COOLANT

Coolant liquid solution is 50% water and 50% antifreeze. This is the ideal mixture for most operating

temperatures and provides good corrosion protection.

This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce

the need for top-ups.

CHAR - 11

Characteristics

Thus, mineral salt deposits formed in the radiator by evaporated water are also minimised and the

efficiency of the cooling system is not affected.

When the temperature drops below zero degrees centigrade, check the cooling system frequently and

add more antifreeze if needed (up to 60% max.).

Use distilled water in the coolant mixture to avoid damaging the engine.

Depending on the freezing temperature of the coolant mixture you wish to achieve, add the percentage

of coolant indicated in the following table to the water:

FREEZING POINT C° (-°F)

Specification Desc./Quantity

-20° (-4) Coolant 35% by volume

-30° (-22) Coolant 45% by volume

-40° (-40) Coolant 55% by volume

NOTE

THE DIFFERENT ANTIFREEZE LIQUIDS HAVE DIFFERENT CHARACTERISTICS. THE DEGREE OF PROTECTION GUARANTEED CAN BE FOUND ON THE LABEL OF THE PRODUCT.

CAUTION

USE ONLY ANTIFREEZE AND CORROSION INHIBITORS WITHOUT NITRITE THAT ENSURE A PROTECTION OF AT LEAST -35°C (-31°F).

TYRES

CAUTION

CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS. THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS SLIPPERY. DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES (MILES). NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES. IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUEL THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER. A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT SIMPLY CLEANED. DO NOT FIT TYRES WITH INNER TUBES ON RIMS FOR TUBELESS TYRES AND VICE VERSA.

Vehicle identification

Chassis number

The chassis number is stamped on the chassis

central bar. Remove the indicated cap placed in-

side the front glove-box in order to read this num-

ber.

CHAR - 12

Characteristics

Engine number

The engine number is stamped near the rear

shock absorber lower support.

CAUTION ALTERING IDENTIFICATION NUMBERS CAN BE SERI-

OUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY.

Dimensions and mass

DIMENSIONS

Specification Desc./Quantity

Max. length 1965 mm (77.36 in)

Max. width 730 mm (28.74 in)

Max. height (to windshield) 1130 mm (44.49 in)

Saddle height 790 mm (31.10 in)

Wheelbase 1360 mm (53.54 in)

Minimum ground clearance 130 mm (5.11 in)

Kerb weight 148 kg (328.28 lb)

Engine

Overall engine capacity 244.29 cm³

Engine revs at idle speed 1600 ± 100 rpm

Throttle body diffuser (throttle body Ø) Electronic injection Ø 32 mm

Transmission

ENGINE TECHNICAL DATA

Specification Desc./Quantity

Engine model M288M

Engine type Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication

system, overhead camshaft.

Bore / stroke 72 mm / 60 mm

Compression ratio 11.0 ± 0.5 : 1

Start-up Electric

Clutch Automatic centrifugal dry clutch

Transmission Automatic

Cooling forced-circulation air cooling driven by a centrifugal pump

Valve clearance Inlet: 0.10

Outlet: 0.15

Supply Vacuum pump

Fuel Use premium unleaded petrol only, with minimum octane rating

of 95 (NORM) and 85 (NOMM).

IGNITION Capacitive discharge ignition, variable advance

Spark plug CHAMPION RG4 - PHP

TRANSMISSION

Specification Desc./Quantity

Gear continuous and automatic variator

Main transmission V-belt

Secondary transmission Gear reduction unit

Engine/wheel total ratio - minimum: 1:2.3

CHAR - 13

Characteristics

Specification Desc./Quantity

Capacities

CAPACITY

Specification Desc./Quantity

Fuel (reserve included) 9 l

Fuel reserve 1.5 l

Engine oil change to service engine 1150 cm³ (70.18 cu.in3)

Engine oil and engine oil filter change 1100 cm³ (67.12 cu.in)

Transmission oil 250 cm³ ( 15.25 cu.in)

Fork oil 135

± 1 cm³ ( 8.24 ± 0.06 cu.in) for each stem

Coolant 1.5 litres (0.39 gal) (50% water + 50% ethylene glycol anti-

Seats 2

Vehicle max. load (rider + passenger + luggage) 210 kg (463 lb)

- maximum: 1:0.815

freeze solution)

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

1 Battery 12V - 12 Ah 2 Fuses 20- 15- 7.5 A 3 (Permanent magnet) Generator 12V - 300W 4 Low-/ high-beam light 12 V - 55 W - H7 5 Tail light 12V - 3 W 6 Turn indicator lights 12V - 10W 7 Rear tail light /stop light 12V - 5W / 21W 8 License plate light 12V - 5W 9 Instrument panel lighting LED 10 Turn indicator warning light LED 11 High-beam warning light LED 12 Low fuel warning light LED 13 Spark plug CHAMPION RG4 PHP 14 Spark plug electrode gap 0.7 ± 0.8 mm ( 0.027 in - 0.031 in) 15 Ignition type Capacitive discharge ignition, variable advance 16 Ignition advance Variable managed by control unit. 5th minimum . 15°>

6000/8000 rpm.

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity

Chassis type High-strength steel tubular chassis, single spar at the front, su-

Steering inclination angle 25.5°

Front suspension Hydraulic action telescopic fork

Front suspension - travel 100 mm (3.94 in)

Rear suspension hydraulic action double-acting shock absorber, adjustable pre-

Rear suspension - travel 80 mm ( 3.15 in)

perimposed double cradle at the rear.

CHAR - 14

Characteristics

Brakes

BRAKES

Specification Desc./Quantity

Front brake Ø 260 mm (10.236 in) disc brake with hydraulic transmission

Rear brake Ø 220 mm (8.6 in) disc brake with hydraulic transmission

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rims Made of light alloy Front wheel rim 2.75 x 15" Rear wheel rim 3.00 x 15"

Tyres Without inner tube (Tubeless)

Front tyre 120/70 - 15'' 56P

Rear tyre 130/80 - 15'' 63P Rear tyre standard inflation pressure 200 kPa (2.0 bar) Front tyre standard inflation pressure 200 kPa (2.0 bar)

Front tyre standard inflation pressure with passenger 200 kPa (2.0 bar) Rear tyre standard inflation pressure with passenger 230 kPa (2.3 bar)

Tightening Torques

Name Torque in Nm

Hub oil drainage plug 15÷17 (11.1 ÷ 12.5 ftlb)

Oil filter fitting on crankcase 27÷33 (19.9÷24.4 ftlb)

engine oil drainage plug/mesh filter 24÷30 (17.7÷22.1 ftlb)

Oil filter 4÷6 (3÷4.4 ftlb)

Oil pump cover screws 7÷9 (5.2÷6.6 ftlb)

Screws fixing oil pump to crankcase 5÷6 (3.7÷4.4 ftlb)

oil pump driving crown gear screw 10÷14 (7.4÷10.3 ftlb)

Oil pump cover plate screws 4÷6 (3÷4.4 ftlb)

Oil sump screws 10÷14 (7.4÷10.3 ftlb)

Minimum oil pressure sensor 12÷14 (8.9÷10.3 ftlb)

Name Torque in Nm

Spark plug 12÷14 (8.9÷10.3 ftlb)

Cylinder head cover screws 6÷7 (4.4÷5.2 ftlb)

Head to cylinder retaining nuts 7±1 + 10±1 + 270° (5.2±0.7 + 7.4±0.7 ftlb + 270°)

Head side fixing screws 11÷12 (8.1÷8.9 ftlb)

Starter ground screw 7÷8.5 (5.2÷6.3 ftlb)

Tappet set screw lock nut 6÷8 (4.4÷5.9 ftlb)

Inlet manifold screws 11÷13 (8.1÷9.6 ftlb)

Timing chain tensioner pad screw 10÷14 (7.4÷10.3 ftlb)

Starter ground bell screw 11÷15 (8.1÷11.1 ftlb)

Timing chain tensioner support screw 11÷13 (8.1÷9.6 ftlb)

Timing chain tensioner central screw 5÷6 (3.7÷4.4 ftlb)

Camshaft retention plate screw 4÷6 (3÷4.4 ftlb)

LUBRICATION

CYLINDER HEAD

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11÷13 (8.1÷9.6 ftlb)

Clutch assembly nut on driven pulley 45÷50 (33.2÷36.9 ftlb)

Driving pulley nut 75÷83 (55.4÷61.3 ftlb)

Transmission cover screws 11÷13 (8.1÷9.6 ftlb)

CHAR - 15

Characteristics

Name Torque in Nm

Driven pulley shaft nut 54÷60 (39.9÷44.3 ftlb)

Rear hub cover screws 24÷27 (17.7÷19.9 ftlb)

FLYWHEEL

Name Torque in Nm

Flywheel cover screw 11÷13 (8.1÷9.6 ftlb)

Stator unit screws 3÷4 (2.2÷3 ftlb) (Apply LOCTITE 242 medium-strength thread-

Flywheel nut 94÷102 (69.4÷75.3 ftlb)

Pick-Up fixing screws 3÷4 (2.2÷3 ftlb)

Screws fixing freewheel to flywheel 13÷15 (9.6÷11.1 ftlb)

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Screws for engine crankcase internal bulkhead (transmission-

side half shaft)

Engine crankcase coupling screws 11÷13 (8.1÷9.6 ftlb)

Starter motor screws 11÷13 (8.1÷9.6 ftlb)

Crankcase timing system cover screw 3.5÷4.5 (2.6÷3.3 ftlb) (Apply LOCTITE 242 medium-strength

lock)

4÷6 (3÷4.4 ftlb)

threadlocker)

HANDLEBAR

Name Torque in Nm

Handlebar to fork retainer 48±20% (35.52 ftlb)

Safety screw 20±20% (14.8 ftlb)

Steering set nut 15±20% (11.1 ftlb)

Steering series fixing lock nut 110±20% (81.4 ftlb)

CHASSIS

Name Torque in Nm

License plate holder support to chassis retainer 25±20% (18.5 ftlb)

Passenger grab handle to chassis retainer 25±20% (18.5 ftlb)

Horn to chassis retainer 10±20% (7.4 ftlb)

Regulator to chassis retainer 10±20% (7.4 ftlb)

Switch to chassis retainer 10±20% (7.4 ftlb)

Control unit to chassis retainer 10±20% (7.4 ftlb)

Fuel tank to chassis retainer 10±20% (7.4 ftlb)

Helmet compartment to chassis retainer 5±20% (3.7 ftlb)

Air deflector to chassis retainer 5±20% (3.7 ftlb)

Coil to chassis retainer 5±20% (3.7 ftlb)

ELECTRICAL SYSTEM

Name Torque in Nm

Starter motor cable retainer 5±20% (3.7 ftlb)

Battery to relay retainer 4±20% (2.96 ftlb)

Starter motor on relay retainer 4±20% (2.96 ftlb)

Battery cable harness ground lead retainer 10±20% (7.4 ftlb)

SADDLE

Name Torque in Nm

Hinge on saddle retainer 7±20% (5.18 ftlb)

LOCKS

Name Torque in Nm

Glove-box lock on cover retainer 4±20% (2.96 ftlb)

Saddle lock on right and left half-tail sections retainer 3±20% (2.22 ftlb)

Saddle lock on helmet compartment retainer 5±20% (3.7 ftlb)

CHAR - 16

Characteristics

INSTRUMENT PANEL

Name Torque in Nm

Right handlebar cover to left handlebar cover retainer 1±20% (0.74 ftlb)

Windshield on handlebar cover retainer 1±20% (0.74 ftlb)

Instrument panel on instrument panel support retainer 2±20% (1.48 ftlb)

Instrument panel support on internal handlebar cover retainer 1±20% (0.74 ftlb)

Internal handlebar cover on handlebar retainer 3±20% (2.22 ftlb)

External handlebar cover on windshield retainer 3±20% (2.22 ftlb)

REAR BODYWORK

Name Torque in Nm

Retroreflector to license plate holder retainer 1.5±20% (1.11 ftlb)

License plate to license plate holder retainer 1±20% (0.74 ftlb)

Rear taillight to right and left half-tail sections retainer 1±20% (0.74 ftlb)

Right and left half-tail sections on helmet compartment retainer 4±20% (2.96 ftlb)

Rear light cover on license plate holder retainer 1±20% (0.74 ftlb)

License plate holder on right and left half-tail sections retainer 3±20% (2.22 ftlb)

License plate holder on rear mudguard chassis retainer 5±20% (3.7 ftlb)

Luggage carrier cover on luggage carrier retainer 1±20% (0.74 ftlb)

Right and left half-tail sections on helmet compartment retainer 1±20% (0.74 ftlb)

Fuel probe lid on helmet compartment retainer 1±20% (0.74 ftlb)

Retainer for lower lock of right and left half-tail sections on right

and left half-tail sections

3±20% (2.22 ftlb)

CENTRAL BODYWORK

Name Torque in Nm

Central inspection cover on helmet compartment retainer 1±20% (0.74 ftlb) Central inspection cover on right and left fairings retainer 3±20% (2.22 ftlb)

Left side inspection cover retainer 3±20% (2.22 ftlb)

Right side inspection cover retainer 3±20% (2.22 ftlb)

Battery cover retainer 3±20% (2.22 ftlb)

Footrest retainer 3±20% (2.22 ftlb)

Right and left lower shield retainer 3±20% (2.22 ftlb)

Glove-box lid on front internal shield retainer 1±20% (0.74 ftlb)

Front internal shield to front external shield retainer 1±20% (0.74 ftlb)

Glove-box net on front internal shield retainer 1±20% (0.74 ftlb)

Glove-box lid reinforcing retainer 1±20% (0.74 ftlb)

Bag hook retainer 1±20% (0.74 ftlb)

Air intake on front internal shield retainer 1±20% (0.74 ftlb)

FRONT AND REAR BRAKE

Name Torque in Nm

Calliper on fork retainer 25±20% (18.5 ftlb)

Calliper on muffler plate retainer 25±20% (18.5 ftlb)

Pipe cable guide on link rod retainer 10±20% (7.4 ftlb)

Pipe cable guide on air deflector retainer 5±20% (3.7 ftlb)

Right and left pump on handlebar retainer 10±20% (7.4 ftlb)

Rear calliper support to muffler plate retainer 25±20% (18.5 ftlb)

Rear calliper support on muffler plate retainer 25±20% (18.5 ftlb)

Front pipe cable guide on fork retainer 10±20% (7.4 ftlb)

FRONT BODYWORK

Name Torque in Nm

Right and left air intake on front internal shield retainer 1±20% (0.74 ftlb)

Right and left turn indicators on front external shield retainer 1±20% (0.74 ftlb)

Front headlamp on front external shield retainer 1±20% (0.74 ftlb)

Front external shield on cover retainer 1±20% (0.74 ftlb)

Front external shield on lower shield retainer 1±20% (0.74 ftlb)

Front mudguard clamp on fork retainer 1±20% (0.74 ftlb)

Front external shield on under-footrest retainer 3±20% (2.22 ftlb)

Front mudguard on clamps retainer 5±20% (3.7 ftlb)

Case on front internal shield retainer 2±20% (1.48 ftlb)

CHAR - 17

Characteristics

Filter housing on engine retainer 8±20% (5.92 ftlb)

Expansion tank on air deflector retainer 4±20% (2.96 ftlb)

FILTER HOUSING

Name Torque in Nm

Sleeve on carburettor retainer 2±20% (1.48 ftlb)

Sleeve on filter housing retainer 2±20% (1.48 ftlb)

COOLING UNIT

Name Torque in Nm

Thermal switch retainer 20±20% (14.8 ftlb)

Head pipe on radiator retainer 2±20% (1.48 ftlb)

Pump pipe on radiator retainer 2±20% (1.48 ftlb)

Radiator on bulkhead retainer 7±20% (5.18 ftlb)

Electric fan on radiator retainer 1±20% (0.74 ftlb)

FRONT WHEEL

Name Torque in Nm

Pin retainer 50±20% (37 ftlb)

Safety screw retainer 10±20% (7.4 ftlb)

LINK ROD

Name Torque in Nm

Connecting rod to chassis retainer 60±20% (44.4 ftlb)

Connecting rod to engine retainer 40±20% (29.6 ftlb)

Chassis connecting rod on engine connecting rod retainer 60±20% (44.4 ftlb)

Silent-block on chassis retainer 50±20% (37 ftlb)

EXHAUST

Name Torque in Nm

Manifold to engine retainer 15±20% (11.1 ftlb) Muffler to manifold retainer 16±20% (11.84 ftlb)

Muffler on plate retainer 25±20% (18.5 ftlb)

Protection on muffler retainer 7±20% (5.18 ftlb)

REAR WHEEL

Name Torque in Nm

Rear wheel retainer 110±20% (81.4 ftlb)

Speed sensor screw retainer 10±20% (7.4 ftlb)

Speed sensor on muffler plate retainer 10±20% (7.4 ftlb)

STAND

Name Torque in Nm

Stand to engine retainer 27±20% (19.98 ftlb)

ENGINE

Name Torque in Nm

Muffler plate on engine 25±20% (18.5 ftlb)

Fuel breather pipe cable guide on crankcase 10±20% (7.4 ftlb)

REAR SUSPENSION

Name Torque in Nm

Right and left shock absorber to chassis retainer 40±20% (29.6 ftlb)

Shock absorber on engine bracket retainer 40±20% (29.6 ftlb)

Shock absorber on muffler plate retainer 40±20% (29.6 ftlb)

Shock absorber bracket on engine retainer 25±20% (18.5 ftlb)

FUEL SUPPLY SYSTEM

Name Torque in Nm

Probe to tank retainer 1.5±20% (1.11 ftlb)

CHAR - 18

Characteristics

Name Torque in Nm

Fuel coupling clamp retainer 1±20% (0.74 ftlb)

Tank to helmet compartment retainer 2±20% (0.74 ftlb)

Petrol pump on helmet compartment retainer 2±20% (1.48 ftlb)

Overhaul data

Assembly clearances

Cylinder - piston assy.

Piston: the category marking is on the piston crown.

Cylinder: the category marking is on the external side of the cylinder.

CYLINDER - PISTON COUPLING CATEGORY

Name Initials Cylinder Piston Play on fitting

Cylinder - Piston M = 1 72.01 ÷ 72.017 71.953 ÷ 71. 960 0.050 ÷ 0. 064 Cylinder - Piston N = 2 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 ÷ 0.064 Cylinder - Piston O = 3 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 ÷ 0.064 Cylinder - Piston P = 4 72.031 ÷ 72.038 71.974 ÷ 71.981 0.050 ÷ 0.064

If only the piston is replaced, check the cylinder category taking into account the CYLINDER - PISTON

COUPLING CATEGORY table.

CAUTION

THERE IS ONLY ONE CYLINDER CODE IN THE SPARE PART CATALOGUE AND IT IS SUPPLIED TOGETHER WITH THE PISTON.

CHAR - 19

Characteristics

Crankcase - crankshaft - connecting rod

CRANKSHAFT / CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity

Half shaft, transmission

side

Half shaft, flywheel side 16.6 +0-0.05 B D = 0.20 ÷ 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 ÷ 0.50

Spacer tool 51.4 +0.05 E D = 0.20 ÷ 0.50

16.6 +0-0.05 A D = 0.20 ÷ 0.50

Slot packing system

Characteristic

Compression ratio

10.5 ÷ 11.5 : 1

CHAR - 20

Characteristics

Distance "A" to be measured is a value of piston recess, it indicates by how much the piston crown

descends below the plane formed by the cylinder crown. The further the piston enters into the cylinder,

the thinner the base gasket to be used should be (to compensate the compression ratio) and vice versa.

NOTE

DISTANCE «A» SHOULD BE MEASURED WITH NO GASKET FITTED BETWEEN THE CRANKCASE AND THE CYLINDER AND AFTER RESETTING THE DIAL GAUGE, WITH SUPPORT, ON A GROUND PLANE

SHIMMING FOR 250 ENGINES

Name Measure A Thickness

Shimming 3.70 - 3.60 0.4 ± 0.05 Shimming 3.60 - 3.40 0.6 ± 0.05 Shimming 3.40 - 3.30 0.8 ± 0.05

Products

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceeds the requirements of API SL, ACEA A3, JASO MA specifications

Oil pressure warning light

The vehicle has an icon on the display and a gen-

eral alarm warning light, on the instrument panel, that light up when the key is turned to «ON». This

light should however go off once the engine is

started.

In case the icon and the telltale light turn on when braking, at idle speed or on a bend, check the oil level and the lubrication system.

Transmissions

THROTTLE GRIP REMOVAL

•

Undo and remove the two screws.

MAIN - 41

Maintenance

•

Remove the throttle grip cable.

Remove the throttle grip.

THROTTLE GRIP REFITTING

•

Carry out the operations but in the re-

verse order, making sure to match the

hole (1) with the pin (2).

Checking the ignition timing

- Remove the plastic cap on the flywheel cover

- Turn the flywheel until the reference mark «T» on

the rotor matches the reference mark on the fly-

wheel cover as shown in the figure (TDC). Make

sure that the reference 4V on the camshaft control

pulley is aligned with the reference point on the

head, as shown in the second figure. If the refer-

MAIN - 42

Maintenance

ence mark is opposite the mark on the head, make

the crankshaft turn once more.

To use this reference mark, remove the spark plug

and make the engine spin opposite its normal di-

rection of rotation applying a calliper spanner to

the camshaft control pulley casing.

Cooling system

Radiator cleaning

•

Remove the front case.

•

Wash the radiator with a pressurised water jet.

•

Blow the radiator with compressed air.

NOTE

IT IS NOT NECESSARY TO REMOVE THE RADIATOR

Level check

•

Stop the engine and wait until it cools down.

•

Remove the front case

•

Make sure that the coolant level in the expansion tank «1» is between the "MIN" and "MAX"

reference marks.

MIN = minimum level. MAX = maximum level.

CAUTION

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

NOTE

PARK THE VEHICLE ON SAFE AND LEVEL GROUND.

Otherwise:

•

Loosen but do not remove the filler cap «2» (by rotating it twice anticlockwise).

•

Wait for some seconds so that any pressure may be purged.

•

Unscrew and remove the cap.

CAUTION

DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID.

MAIN - 43

Maintenance

•

Top-up with recommended coolant un-

til the fluid level is near the "MAX" ref-

erence mark.

•

Do not exceed this level. Otherwise,

the coolant will spill out when the en-

gine is running.

•

Refit the filler cap «2».

CAUTION IF THERE IS AN EXCESSIVE CONSUMPTION OF COOL-

ANT OR WHEN THE EXPANSION TANK REMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT. FOR REPAIRS, TAKE YOUR VEHICLE TO AN OFFICIAL DERBI DEALER.

Recommended products

SPECIAL AGIP PERMANENT fluid Coolant

Biodegradable coolant, ready for use, with "long

life" technology and characteristics (pink). Freez-

ing protection up to -40°. According to CUNA

956-16 standard.

Top-up

•

Top-up with coolant until the fluid level is near the "MAX" level.

•

Refit the filler cap «2».

•

Refit the front case.

CAUTION

DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.

CAUTION

IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK REMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT. FOR REPAIRS, TAKE YOUR VEHICLE TO AN OFFICIAL DERBI DEALER.

Recommended products

SPECIAL AGIP PERMANENT fluid Coolant

Biodegradable coolant, ready for use, with "long life" technology and characteristics (pink). Freezing

protection up to -40°. According to CUNA 956-16 standard.

Braking system

The following operations refer to both braking systems.

CAUTION

PURGE THE AIR IN THE SYSTEM IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER, EXCESSIVE ELASTICITY OR AIR BUBBLES IN THE CIRCUIT. DO NOT USE OR MIX DIFFERENT SILICON- OR PETROLEUM-BASED COOLANT TYPES.

MAIN - 44

Maintenance

PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIRCUIT.

Level check

CAUTION

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

NOTE

THE FOLLOWING OPERATIONS REFER TO BOTH BRAKING SYSTEMS. Checking

NOTE

PARK THE VEHICLE ON SAFE AND LEVEL GROUND.

•

Park the vehicle on its centre stand on safe and level ground.

•

Make sure that the fluid level in the reservoir is above the "MIN" mark.

If the fluid does not reach at least the "MIN" reference mark:

CAUTION

BRAKE FLUID LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN.

•

Check the brake pads for wear.

•

Top-up fluid level if the break pads and/or disc are not to be replaced.

Top-up

•

Undo and remove the two screws.

CAUTION RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE

FRONT BRAKE LEVER WHEN THE SCREWS ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COVER HAS BEEN REMOVED. PLACE A CLOTH UNDER THE BRAKE FLUID RESERVOIR TO PROTECT IT FROM ANY FLUID SPLASHES.

MAIN - 45

Maintenance

•

Lift and remove the cover «1».

•

Remove the gasket «2».

•

Top-up the reservoir «3» with brake

fluid up to the right level.

•

Follow the reverse order for refitting the

components.

CAUTION DO NOT SHAKE THE VEHICLE TO AVOID BRAKE FLUID

SPLASHING DURING TOP-UP. CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE

FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.

CAUTION DO NOT FILL UP THE TANK TO THE MAXIMUM, BUT JUST

OVER THE ''MIN'' LEVEL. TOP-UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. IT IS ADVISABLE NOT TO TOP-UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BECAUSE YOUR RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS.

System check

Rear brake calliper

To carry out a quick pad wear check:

•

Rest the vehicle on its centre stand.

•

Visually check with a light and a mirror

between the calliper and the brake

pads, in the following way:

•

From the back top side for both brake

pads.

When the friction material thickness (even if in one

pad only) is worn to about 1.5 mm (0.05 in),

replace both brake pads.

MAIN - 46

Maintenance

Front brake calliper

THIS OPERATION APPLIES TO BOTH FRONT

CALLIPERS

To check brake pad wear:

•

Rest the scooter on its centre stand.

•

Remove the front brake calliper.

•

Carry out a visual inspection.

Replace both brake pads when the friction material

(even if in one brake pad only) is worn to about 1.5

mm (0.05 in).

MAIN - 47

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Troubleshooting

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE WEAR

Possible Cause Operation

Incorrect valve adjustment Adjust valve clearance adequately

Overheated valves Remove the head and the valves, grind or replace the valves

Deformed/worn valve seat Replace the head unit

Worn cylinder, Piston ring worn or broken Replace the cylinder piston unit or the piston rings

Piston rings worn, broken or not adequately fitted Replace the cylinder piston unit or just the rings

Oil leakage from the couplings or the gaskets Check and replace the gaskets or restore the coupling sealing

Valve oil seal worn Replace the valve oil seal Valve guides worn Check the head unit and replace it, if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause

By-Pass remains open Check the By-Pass and replace it, if required. Carefully clean

Oil pump with excessive clearance Check the sizes of the oil pump components

Oil filter too dirty Replace the cartridge filter

Oil level too low Fill up to the correct level with recommended oil type

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause

Faulty clutch Check that there is no grease on the masses. Check that the

faying surface between the clutch masses and the clutch bell

is mainly in the middle and with equivalent characteristics on

the three masses. Check that the clutch bell is not scored or

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause Operation

Seals faulty or damaged Replace the shock absorber. Check the wear conditions of the

Operation

the By-Pass area.

Operation

abnormally worn

head set cups and the adjustments.

TROUBL - 49

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system

KEY:

ELE SYS - 51

Electrical system

1. Multiple connectors

2. Fuel sensor

3. Instrument panel

4. Water thermistor

5. Speed sensor

6. Left light switch

7. Horn

8. Key switch

9. Front stop switch

10. Rear stop switch

11. Right light switch

12. Rear left turn indicator

13. Tail light/stop light twin bulb

14. Rear right turn indicator

15. Complete rear light

16. License plate light

17. Stop lights/start-up enabling switch relay

18. -

19. Start-up relay

20. Starter motor

21. Main fuses

22. Auxiliary fuses

23. Plug socket

24. Battery

25. HV coil

26. Spark plug

27. Automatic starter

28. CDI control unit

29. Connector for oil sensor (only )

30. Oil pressure sensor

31. Pick up

32. Generator

33. Voltage regulator

34. Thermoswitch

35. Fan

36. Glove-box light

37. Glove-box light switch

38. Front right turn indicator

ELE SYS - 52

Electrical system

39. Front headlamp tail light

40. High-beam bulb

41. Low-beam bulb

42. Front left turn indicator

43. Complete front headlamp

44. Det. Blinker (only)

45. Kit for det. blinker (only) CABLE COLOUR Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red V green Vi purple Ro pink

Components arrangement

ELE SYS - 53

Electrical system

KEY:

1. Front turn indicators

2. Electric fan

3. Instrument panel

4. Battery

5. Coil

6. Rear light unit

7. Fuses

8. Spark plug

9. Fuel level sensor

10.Automatic starter

11.Voltage regulator

12.Control unit

13.Start-up relay

14.Horn

15.Front headlamp

16.Pick-up sensor

17.Water temperature sensor

18.Generator

ELE SYS - 54

Electrical system

1 Front turn indicators

Turn indicator light: 12V - 10W

2 Electric fan

3 Instrument panel

4 Battery

12V - 10 Ah

ELE SYS - 55

Electrical system

5 Coil

Primary resistance: 0.2±10% Ohm at 20 °C (68 °

Secondary resistance: 2.9±10% Ohm at 20 °C (68

°F)

6 Rear light unit

Tail light / stop light: 12V - 5/21W

Turn indicator light: 12V - 10W

7 Fuses Main Fuses: 20A fuse (1):

From the battery to ignition switch, voltage regu-

lator, electric fan.

15A fuse (2):

From the ignition switch to all light loads and horn.

Auxiliary fuses: 15A fuse (3):

From the ignition switch to all light loads and horn.

15A fuse (4):

From the ignition switch to ignition.

8 Spark plug

NGK CR7EB, alternatively:

NGK CR8EB

NGK CR9EB

CHAMPION RG6YC

CHAMPION RG4HC

Spark plug electrode gap: 0.7. 0.8mm

Spark plug cap resistance: 5 K

ELE SYS - 56

Electrical system

9 Fuel level sensor

Full tank 100 ± 10% Ohm

Full tank 1200 ± 10% Ohm

10 Automatic starter

Approximately 30 Ohm at 20 °C (68 °F)

11 Voltage regulator

(SH640D)

Recharging voltage:

- to terminals, off-load: 13/15 V at 5000 RPM

12 Control unit

MARELLI

ELE SYS - 57

Electrical system

13 Start-up relay

12 V / 150 A

14 Horn

LEB 12 V 4A

15 Front headlamp

Low-/high-beam lights: 12 V - 55 W . H7

Front position light: 12V - 5W

16 Pick-up sensor

Winding resistance: 105±10% Ohm at 20 °C (68 °F)

17 Water temperature sensor 100 (°C) 212 (°F) 144 Ohm 80 (°C) 176 (°F) 262 Ohm

60 (°C) 140 (°F) 512 Ohm

40 (°C) 104 (°F) 1090 Ohm

ELE SYS - 58

Electrical system

18 Generator

permanent magnet, 12 V - 300 W

Stator coil resistance:

0.1 - 1 Ohm at 20 °C (68 °F)

Off-load generated voltage:

> 50 V to 5000 RPM

CABLE COLOUR Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple

NOTE

NUMBERS DISPLAYED ON THE SPECIFIED ELECTRICAL CIRCUIT DIAGRAMS CORRESPOND TO THE GENERAL ELECTRIC CIRCUIT DIAGRAM.

Disconnect the two electrical connectors strictly observing the following procedure:

•

Press the relevant safety hooks, if any.

CAUTION

DO NOT PULL THE CABLES TO DISCONNECT THE TWO CONNECTORS.

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

•

If there are signs of dirt, rust, humidity, etc., clean the connector internal parts carefully by

using a pressurised air jet.

•

Make sure that the cables are correctly linked to the connector internal terminal ends.

NOTE

THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND

ELE SYS - 59

Electrical system

Then fit the two connectors making sure that they

couple correctly (if the relevant safety hooks are

provided, you will hear them "click" into place).

Conceptual diagrams

1. Magneto flywheel-Pick up

2. Voltage regulator

3. Injection electronic control unit

4. ECU Diag.

5. Engine stop switch

6. Main fuse

7. Key switch

8. Injection load remote control

9. Auxiliary fuses

10. Battery

ELE SYS - 60

Electrical system

11. Starter motor

12. Start-up remote control switch

13. Starter button

14. Front stop switch

15. Rear stop switch

16. Horn

17. Horn button

18. Plug socket

19. Stop light remote control

20. Rear light unit A. Tail light/stop light twin bulb B. License plate light bulb

21. Front headlight assembly A. Tail light B. Low-beam headlight bulb C. High-beam headlight bulb

22. Light switch

23. Turn indicator control device

24. Turn indicator bulbs

25. Turn indicator switch

26. Instrument panel diag.

27. Fuel level transmitter

28. Scroll switch

29. Instrument panel

30. Oil pressure sensor

31. Electric fan remote control

32. Electric fan

33. Speed sensor

34. Engine temperature sensor

35. Fuel pump

36. Fuel injector

37. Lambda probe

38. Spark plug

39. HV coil

40. Fall sensor Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

ELE SYS - 61

Electrical system

Ignition

1. Magneto flywheel-Pick up

3. Injection electronic control unit

5. Engine stop switch

6. Main fuse

7. Key switch

8. Injection load remote control

9. Auxiliary fuses

10. Battery

38. Spark plug

39. HV coil Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

ELE SYS - 62

Electrical system

Battery recharge and starting

1. Magneto flywheel-Pick up

2. Voltage regulator

6. Main fuse

7. Key switch

9. Auxiliary fuses

10. Battery

11. Starter motor

12. Start-up remote control switch

13. Starter button

14. Front stop switch

15. Rear stop switch

19. Stop light remote control

20. Rear light unit A. Tail light/stop light twin bulb Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

ELE SYS - 63

Electrical system

Level indicators and enable signals section

3. Injection electronic control unit

5. Engine stop switch

6. Main fuse

7. Key switch

8. Injection load remote control

9. Auxiliary fuses

10. Battery

27. Fuel level transmitter

28. Scroll switch

29. Instrument panel

30. Oil pressure sensor

33. Speed sensor

34. Engine temperature sensor

35. Fuel pump

36. Fuel injector

37. Lambda probe

40. Fall sensor Key

ELE SYS - 64

Electrical system

Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Devices and accessories

1. Magneto flywheel-Pick up

3. Injection electronic control unit

5. Engine stop switch

6. Main fuse

7. Key switch

8. Injection load remote control

9. Auxiliary fuses

10. Battery

38. Spark plug

39. HV coil Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:

Red Ve: Green Vi: Purple

ELE SYS - 65

Electrical system

Lights and turn indicators

1. Magneto flywheel-Pick up

2. Voltage regulator

6. Main fuse

7. Key switch

9. Auxiliary fuses

10. Battery

20. Rear light unit A. Tail light/stop light twin bulb B. License plate light bulb

21. Front headlight assembly A. Tail light B. Low-beam headlight bulb C. High-beam headlight bulb

22. Light switch

23. Turn indicator control device

24. Turn indicator bulbs

25. Turn indicator switch

29. Instrument panel

ELE SYS - 66

Electrical system

Key Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Checks and inspections

Battery recharge circuit

•

Remove the battery from the vehicle.

•

Charge the battery with a slow charge (current rating equal to 1/10 of the battery capacity)

for at least 10 hours: Refit battery to the motorcycle upon delivery to customer, that is to say,

when a mileage is set.

•

Install the battery on the motorcycle, connect the leads and the breather pipe.

•

If the motorcycle is not used for a long period, it is necessary to recharge it periodically (at

least once a month) for at least 10 hours (for instance, during the long winter break).

Electric characteristic

Battery

12V - 12 Ah

CHECK

•

In case of malfunction, first check that the recharge system works properly,

•

To check the battery,

•

remove the battery from the vehicle as follows:

Visually check that :

- the container (outer casing) does not leak.

Charge the battery slowly for at least 10 hours.

•

If the off-load voltage is lower than 12V, the battery should be certainly replaced.

COVERED BY WARRANTY

These batteries are not recognised by the warranty if they show:

- mechanical cracks (for example, container is damaged, poles bent, etc.);

- general sulphation (attributable to a wrong activation or use of the battery);

- low electrolyte level (to solve the shipping problem, just close the breather tube with the specific rubber

cap).

ELE SYS - 67

Electrical system

SAFETY SPECIFICATIONS

CAUTION REMEMBER THAT THE ELECTROLYTIC FLUID CONTAINS

SULPHURIC ACID. AVOID CONTACT WITH YOUR SKIN OR CLOTHES AND KEEP THE BATTERY AWAY FROM HIGH HEAT SOURCES OR SPARKS, SPECIALLY WHEN THE BATTERY IS BEING CHARGED, BECAUSE THE HYDROGEN RELEASED CAN BE HIGHLY EXPLOSIVE.

Dashboard

KEY:

1. Service indicator

2. Oil pressure gauge

3. Digital clock

4. Coolant temperature gauge

5. Multifunction digital computer

6. Multifunction indicator: total odometer (ODO) / trip odometer (TRIP) / battery voltage «A»

USER INTERFACE Multifunction indicator functions

Several functions can be selected with the MODE «2» button on the handlebar right side control: clock

adjustment, the total odometer (ODO) function, the trip odometer (TRIP) function, battery voltage read-

ings and trip odometer reset.

Total odometer (ODO) function

When the instrument panel lights on, the multifunction display «1» shows the odometer (ODO) function. Trip odometer (TRIP) function. When the odometer (ODO) function is displayed, press the MODE «2» button once to view the TRIP function. Press the MODE «2» button longer than three seconds to reset

the counter of the trip times stored.

Battery voltage

When the odometer (ODO) function is displayed, press the MODE «2» button twice to view the battery

voltage.

Unit of measurement - km/mi conversion

When the battery voltage is shown on the multifunction display «1», the unit of measurement can be shifted form kilometres (km) to Miles (mi) by holding down the MODE «2» button longer than ten sec-

onds. While the button is being pressed, the legend of the unit of measurement being used flashes.

Unit conversion is cancelled if the button is not pressed within ten seconds.

ELE SYS - 68

Electrical system

Clock adjustment

•

Press and hold the MODE «2» button longer than three seconds. The colon dividing hours-

minutes starts flashing.

•

Each time the MODE «2» button is pressed, the hour value is increased for adjustment.

•

Pressing the MODE «2» button again longer than three seconds activates the minutes ad-

justment. The value displayed increases each time the MODE «2» button is pressed.

Press the MODE «2» button longer than three seconds to go back to the hour adjustment. If no button

is pressed within three seconds, the display automatically exits the clock adjustment function.

NOTE

FOR SAFETY REASONS, ADJUST THE CLOCK ONLY WHEN YOUR VEHICLE IS STOPPED.

Data check function

SERVICE

When the vehicle is started and right after the ignition check, if there are less than 300 km (200 mi) left

to the next Service, the specific icon flashes for 5 seconds. Once the service mileage has been reached,

the icon remains steadily until the Service is reset.

The warning light can be zero set even if the mileage is lower, up to 300 km (200 mi), compared with

the Service mileage. During the 300 km (200 mi) before the service warning light comes on, the light

flashes 5 times each time the key is set to ''ON''.

The light should turn on first at 1000 km (625 mi). Successive times are strictly at 10000 km (6215 mi),

20000 km (12430 mi), etc.

RESET

Hold the MODE button down.

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

During this operation the service icon flashes at a

1 Hz frequency.

ELE SYS - 69

Electrical system

When the battery is attached the software code is

displayed on the instrument panel and the needle

goes from 0 to the end of the scale and back to zero. With the key to ''ON'' for 3 seconds all the

segments of the display will light up (except for the

words Miles and Km) as well as all the foreseen

warning lights. The instrument panel backlighting

is always lit up. The analogue instrument goes to

zero. After the check all the instruments immedi-

ately show the values of the measurements de-

tected.

Oil pressure sensor

This is a normally open contact; it signals an alarm

in the oil pressure. In case of malfunction a ground

signal is indicated, the general alarm warning light

and the corresponding icon on the display turn on.

Battery failure

If the battery voltage is below approx. 10.0 V or exceeds approx. 16 V the battery icon flashes at a 1Hz

frequency. The general alarm warning light turns on.

Fuel level sensor

If the instrument panel detects an infinite resist-

ance (interrupted circuit), the general alarm warn-

ing light turns on and the corresponding icon on

the display flashes (the reserve warning light does

not turn on).

ELE SYS - 70

Electrical system

If the instrument detects a null resistance (short

circuit), all the segments light up but no other in-

dication is shown.

Temperature sensor

The general alarm warning light turns on when the

temperature is above 115°C (approx. 25 Ohm).

If the instrument panel detects an infinite resist-

ance (interrupted circuit), the general alarm warn-

ing light turns on and the corresponding icon on

the display flashes.

If the instrument panel detects a null resistance

(short circuit), all the segments light up, the gen-

eral alarm warning light turns on and the corre-

sponding icon on the display flashes.

1. Each time the battery is attached, the fuel gauge indicates full tank regardless of the quantity of fuel

in the tank; it takes approximately 80 seconds to update. After that, the gauge indicates the correct

value.

ELE SYS - 71

Electrical system

2. If the tank is emptied with the engine off (with an external pump), when the vehicle is started, the

gauge shows the fuel level in the tank before the emptying. In this case, also wait 80 seconds to read

the true level.

This happens because the multifunction digital computer has saved in its memory the fuel level in the tank at the moment the key was turned to ''OFF''; when the battery is first attached, there is no level

stored in the memory and the tank is emptied by means of an external pump, the computer is not able

to detect it.

Connectors

Dashboard

PINOUT

The connector diagram seen on the instrument

panel and the relevant pinout are shown in the fig-

ure.

The numbers are also stamped on the plastic part

of the connectors and also on the connector body.

KEY: A: Black B: Grey

CONNECTOR PINOUT

Specification Desc./Quantity

1 Key Positive 2 Right indicator input 3 Speed sensor power supply 4 RPM 5 Speed sensor ground lead 6 General grounding 7 Neutral input 8 Function grounding 9 Function grounding (optional) 10 Function grounding (optional) 11 Battery Positive 12 Left indicator input 13 High-beam lights input 14 Speed sensor input 15 EFI input 16 K Line 17 Oil pressure sensor 18 Fuel Level Sensor 19 Water Temperature Sensor 20 Mode

ELE SYS - 72

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Engine from vehicle

Exhaust assy. Removal

CAUTION

ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY.

Silencer removal

•

Rest the vehicle on its centre stand.

•

Loosen the clamp (1) fixing the exhaust

silencer to the manifold.

•

Undo and remove the three fixing

screws (2).

•

Remove exhaust silencer.

CAUTION

ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY.

•

Remove the rear central cover.

•

Unscrew and remove the two fixing

nuts of the exhaust manifold.

CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL

OFF.

•

Disconnect the lambda probe connec-

tor.

ENG VE - 74

Engine from vehicle

•

Undo and remove the three fixing

screws of the exhaust silencer.

•

Remove the exhaust system.

Removal of the engine from the vehicle

Preventively remove:

•

Helmet compartment.

•

Rear central cover.

•

Right and left fairings.

•

Tail section.

•

Muffler silencer.

•

Rear brake calliper.

•

Throttle body.

•

Remove the footrest lower protection

by sliding it upwards and turning it.

•

Get a container of adequate capacity

to collect the fluid and place it under the

cooling system pump.

•

Remove the expansion tank cap.

•

Loosen the clamp and remove the ra-

diator - pump pipe and allow the cool-

ant to drain into the collecting contain-

er.

•

Undo the screw and remove the cable

guide.

ENG VE - 75

Engine from vehicle

•

Unscrew the spark plug tube and re-

lease its cable from any retainer.

•

Disconnect the lambda probe connec-

tor.

•

Remove the injector connector.

•

Remove the fast-release fittings from

the injector support.

ENG VE - 76

Engine from vehicle

•

Remove the water temperature sensor

connector.

•

Unscrew and remove the starter motor

supply and ground nuts.

•

Disconnect the starter motor supply

and ground cables and leads.

•

Working from the vehicle left side, re-

move the generator connectors.

•

Cut any retaining straps.

•

Remove the fuel bleeding pipe.

ENG VE - 77

Engine from vehicle

•

Hold the vehicle chassis by means of a

hoister.

•

Working from the left side, unscrew

and remove the nut and slide off the

fixing pin of the shock absorber.

•

Working from the left side, unscrew

and remove the nut and slide off the

fixing pin of the shock absorber.

•

Working on the right side, unscrew and

remove the nut.

•

From the left side, slide off the pin and

collect the washer and the spacer.

•

Remove the engine by pulling it back-

wards.

ENG VE - 78

INDEX OF TOPICS

ENGINE ENG

Engine

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

Automatic transmission

Transmission cover

- To remove the transmission cover, it is necessary

to remove the plastic cover first by inserting a

screwdriver in the slotted holes. Using the clutch

bell lock wrench shown in the figure, remove the

driven pulley shaft lock-nut and washer.

Specific tooling

AP8140661 Lock wrench for clutch bell

- Pull out the cap/dipstick from the engine oil filling

tube.

- Remove the 10 screws.

- Now remove the transmission cover.

NOTE WHEN REMOVING THE TRANSMISSION COVER, BE

CAREFUL NOT TO DROP THE CLUTCH BELL.

Air duct

- Remove the transmission compartment air intake

cover shown in the photograph.

ENG - 80

Engine

- Remove the 5 screws on the two different levels,

as well as the small casing.

Removing the driven pulley shaft bearing

- Remove the seeger ring from the inside of the

cover.

- Remove the bearing from the crankcase.

Specific tooling

020376Y Adapter handle 020375Y 28x30 mm punch 020412Y Clutch oil seal punch D 15 mm

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase internal side so as not

to damage the coated surface.

- Insert the bearing in its housing.

- Refit the seeger ring.

CAUTION REST THE COVER ON A SUITABLE SURFACE TO AVOID

DAMAGING THE COVER COAT. NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE AT

EVERY REFIT

Specific tooling

020376Y Adapter handle 020357Y 32x35 mm punch 020412Y Clutch oil seal punch D 15 mm

ENG - 81

Engine

Baffle roller

Plastic roller

- Check that the roller shows no signs of abnormal

wear and that it rotates freely.

- Remove the special fixing screws as indicated in

the photograph

- Check the roller outside diameter does not have

defects that could jeopardise belt functioning

- For refitting, place the roller with the belt contain-

ment edge on the engine crankcase side

- Tighten the screw to the prescribed torque.

Locking torques (N*m)

Belt support roller screw 11÷13 (8.1÷9.6 ftlb)

Removing the driven pulley

- Remove the clutch bell and the entire driven pul-

ley assembly.

NOTE THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE

DRIVING PULLEY IS MOUNTED.

ENG - 82

Engine

Inspecting the clutch drum

- Make sure that the clutch bell is not worn or dam-

aged.

- Measure the clutch bell inside diameter.

Characteristic

Clutch bell max. value

Max. value: Ø 135 mm

Clutch bell standard value

Standard value: Ø 134 ÷ 134.2 mm

Checking the bell working surface eccentricity

- Fit the bell on a driven pulley shaft with 2 bearings

(inside diameter: 15 and 17 mm).

- Lock with the original spacer and nut.

- Place the bell/shaft assembly on the support to

check the crankshaft alignment.

- Using a feeler pin gauge and the magnetic base,

measure the bell eccentricity.

- Repeat the measurement at 3 positions (Central,

internal, external).

- In case of anomalies, replace the bell.

Characteristic

clutch bell check: Limit eccentricity.

Admissible limit eccentricity: 0.15 mm

Specific tooling

AP8140915 Crankcase check

ENG - 83

Engine

Inspecting the clutch

- Check the thickness of the clutch mass friction

material.

- The masses must exhibit no traces of lubricants;

in that case, check the driven pulley unit seals.

NOTE UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-

TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING.

CAUTION DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID

VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Removing the clutch

Fit the special driven pulley spring compressor tool:

- Fit the driven pulley assembly on the tool by inserting the 3 pins in the ventilation holes on the mass

holder support.

- Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the

clutch nut.

- Use the special multipurpose wrench to remove the nut fixing the clutch.

- Disassemble the driven pulley into its components (Clutch and spring with plastic fitting).

CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST TOUCH THE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.

Specific tooling

AP8140665 Adapter for clutch assembly removal AP8140259 Universal tool for clutch assemblies AP8140300 55 mm wrench

ENG - 84

Engine

Pin retaining collar

- Simultaneously turn and pull the collar manually

to remove it.

NOTE USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY. NOTE BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN

TOO FAR TO AVOID DAMAGING THE O-RING SEAL.

- Remove the 4 torque server pins and pull the half-

pulleys apart.

Removing the driven half-pulley bearing

- Check there are no signs of wear and/or noise;

otherwise, replace it.

- Remove the snap ring using two flat blade screw-

drivers.

- Place pulley bushing on the threaded side ade-

quately on a wood support.

- Using a hammer and pin, knock the ball bearing

out as shown in the figure.

- Support the pulley properly.

Specific tooling

001467Y035 Bell for OD 47-mm bearings

ENG - 85

Engine

- Remove the roller bearing using the specific

punch.

Specific tooling

020376Y Adapter handle 020456Y Ø 24 mm punch 020363Y Crankshaft oil seal punch D 20 mm

Inspecting the driven fixed half-pulley

•

Measure the outside diameter of the

pulley bushing.

•

Check the surface in contact with the

belt to make sure there are no signs of

abnormal wear.

•

Check the riveted joints work properly.

•

Check the evenness of the surface in

contact with the belt.

Characteristic

Half-pulley minimum diameter

Minimum diameter allowed: Ø 40.96 mm

Half-pulley standard diameter

Standard diameter: Ø 40.985 mm

wear limit

0.3 mm

ENG - 86

Engine

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the 2 O-

rings;

- Measure the inside diameter of the movable half-

pulley bushing.

- Check the contact surface with the belt to make

sure there are no signs of abnormal wear.

- Check the riveted joints are functional.

- Check the evenness of the belt contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Specification Desc./Quantity

wear limit 0.3 mm

standard diameter Ø 41,000 ÷ 41,035

Maximum diameter admitted Ø 41.08 mm

Refitting the driven half-pulley bearing

- Place pulley bushing on the threaded side ade-

quately on a wood support.

- Assemble a new roller casing as shown in the

figure.

- To fit the new ball bearing, follow the example in

the picture using a specific punch for roller casing.

- Assemble the seeger ring

NOTE FIT THE BALL BEARING SO THAT THE SHIELD IS VISIBLE.

ENG - 87

Engine

Specific tooling

020376Y Adapter handle 020375Y 28x30 mm punch AP8140662 Punch for roller casing

Refitting the driven pulley

- Insert the new oil seals and O-rings on the mov-

able half-pulley.

- Lightly grease the O-rings (A) shown in the figure.

- Fit the half-pulley on the bushing.

Check that the pins are not worn and proceed to

refit them in the relative hollows.--

- Refit the torque server closing collar.

- Using a curved-spout grease gun, lubricate the

driven pulley assembly with approximately 6

grams of grease. Apply the grease through one of

the holes in the bushing until grease comes out

through the hole on the opposite side. This proce-

dure is necessary to prevent the presence of

grease beyond the O-rings.

NOTE THE TORQUE SERVER CAN BE GREASED WITH BEAR-

INGS FITTED OR WHEN THEY ARE BEING REPLACED; IT MAY BE EASIER TO GREASE TORQUE SERVER WHEN THE BEARINGS ARE BEING SERVICED.

Recommended products

AGIP GREASE 30 Grease for steering bearings, pin seats and swinging arm

ENG - 88

Engine

Specific tooling

AP8140664 Guide to mount the movable driven pulley

Inspecting the clutch spring

- Measure the length of the movable driven half-

pulley spring, when unloaded.

Characteristic

Standard length

123 mm

limit after use

118 mm

Refitting the clutch

- Assemble the spring, clutch and driven pulley.

- Fit the clutch body on the appropriate tool with the adaptor

- Insert the lever pin in the hole of the adaptor ring.

- Tighten the fixing nut to the prescribed torque.

NOTE

WHEN PRELOADING THE SPRING, BE CAREFUL NOT TO DAMAGE THE PLASTIC STOP OF THE SPRING AND THE BUSHING THREADING.

NOTE

FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED CONTACTING THE CLUTCH.

Specific tooling

AP8140259 Universal tool for clutch assemblies AP8140665 Adapter for clutch assembly removal AP8140300 55 mm wrench

Locking torques (N*m)

Clutch assembly nut on driven pulley 45÷50 (33.2÷36.9 ftlb)

ENG - 89

Engine

Refitting the driven pulley

- Refit the clutch bell.

Drive-belt

- Make sure that the driving belt is not damaged.

- Check belt for correct width.

Characteristic

Driving belt 250 4T - minimum width

19.5 mm

Driving belt 250 4T - standard width

21.3 ± 0.2 mm

During the wear checks foreseen in the scheduled

maintenance services, check that the rim bottom

of the toothing does not show signs of incisions or

cracking (see figure): the rim bottom of the tooth

must not have incisions or cracking; if it does,

change the belt.

ENG - 90

Engine

Removing the driving pulley

- Turn the crankshaft until the slots of the pulley

are on a horizontal axis

- With the specific tool remove the fixing nut, the Belleville spring and its washer

- Remove the stationary driving half-pulley and the steel washer in contact with it

Specific tooling

AP8140535 Front pulley fitting/removal

Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inside

diameter.

- Measure the outside diameter of the pulley sliding

bushing shown in the figure.

- Check that the rollers are not damaged or worn.

- Check the guide shoes for the variator roller con-

trast plate are not worn.

- Check that there is no wear in the roller housings

or the surfaces in contact with the belt on both half-

pulleys.

- Check that stationary driving pulley does not

show signs of abnormal wear on the grooved edge

and on the surface in contact with the belt.

- Check that the O-Ring is not deformed.

CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic

movable driving half-pulley bushing: Standard Diameter

26.000 ÷ 26.021 mm

ENG - 91

Engine

movable driving half-pulley bushing: Max. diameter admitted

Ø 26.12 mm

sliding bushing: Standard Diameter

Ø 25.959 ÷ 25.98 mm

sliding bushing: Minimum diameter admitted

Ø 25.95 mm

roller: Standard Diameter

Ø 20.5 ÷ 20.7 mm

roller: Minimum diameter admitted

Ø 20 mm

Refitting the driving pulley

- Preassemble the movable half-pulley with the

roller contrast plate by placing the rollers in their

housings with the larger support surface touching

the pulley according to the direction of rotation.

- Check that the roller contact plate does not show

flaws or is damaged on the grooved edge.

- Fit the entire bushing assembly on the crank-

shaft.

- Fit the driven pulley/Clutch/belt assembly to the

engine.

ENG - 92

Engine

- Fit the steel shim contacting the bushing and the stationary driving half-pulley.

- Install the appropriate tool as described in the removal phase.

- Tighten the nut and washer to the prescribed torque.

Specific tooling

AP8140535 Front pulley fitting/removal

Locking torques (N*m)

Driving pulley nut 75÷83 (55.4÷61.3 ftlb)

Refitting the transmission cover

- Check there are 2 centring dowels and that the

sealing gasket for the oil sump has been ade-

quately fitted on the transmission cover.

- Replace the cover by tightening the 10 screws to

the prescribed torque.

- Refit the oil filling cap dipstick.

- Refit the steel washer and the driven pulley nut.

- Tighten the nut to the specified torque using the

lock wrench and the torque wrench tools.

- Refit the plastic cover.

Specific tooling

AP8140661 Lock wrench for clutch bell

Locking torques (N*m)

Transmission cover screws 11÷13 (8.1÷9.6 ftlb) Driven pulley shaft nut 54÷60 (39.9÷44.3 ftlb)

End gear

ENG - 93

Engine

Removing the hub cover

- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the

figure.

- Remove the hub cover and the relevant gasket.

Removing the wheel axle

- Remove the wheel axle with gear.

- Remove the intermediate gear.

Removing the hub bearings

- Check the status of the bearings being examined (wear, clearance and noise).

ENG - 94

Engine

Removing the wheel axle bearings

- Remove the seeger ring from the outside of the

hub cover.

- Support the hub cover and expel the bearing.

- Remove the oil seal as shown in the figure using

the specific tool.

Specific tooling

020376Y Adapter handle 020477Y 37-mm Adaptor 020483Y 30 mm guide AP8140916 Hub cover support

Removing the driven pulley shaft bearing

- Should the driven pulley shaft, its bearing and oil

guard be removed, take out the transmission cover

and the clutch assembly as described above.

- Extract the driven pulley shaft from its bearing.

- Remove the oil guard using a screwdriver; work-

ing from inside the bearing and being careful not

to damage the housing, make it come out on the

belt transmission side.

- Remove the seeger ring indicated in the figure.

ENG - 95

Engine

- Remove the driven pulley shaft bearing.

Specific tooling

020376Y Adapter handle 020375Y 28x30 mm punch 020363Y Crankshaft oil seal punch D 20 mm

Inspecting the hub shaft

- Check the three shafts for wear or distortions on

the toothed surfaces, on the bearing housings and

the oil seal positions.

- In faults are found, replace the damaged parts.

Inspecting the hub cover

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

- Check the capacity of both the bearings and the wheel oil seal.

- In case of faults, replace the damaged parts.

ENG - 96

Engine

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface.

- warm the cover crankcase with the specific heat

gun.

- Fit the wheel shaft bearing with a modular punch

as shown in the figure.

- Fit the seeger ring.

- Fit the oil guard with its sealing lip facing the hub

internal side and place it flush with the internal

surface using the specific tool used on the 52-mm side.

The 52-mm side of the adaptor should face the

bearing.

Specific tooling

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

ENG - 97

Engine

Refitting the hub cover bearings

To fit the hub box bearings, the engine crankcase

and the cover should be heated with the specific

heat gun.

- The three 15-mm bearings must be fitted using

the appropriate tools:

The 42-mm side of the adaptor should face the

bearing.

Specific tooling

020150Y Air heater support 020151Y Air heater 020376Y Adapter handle 020359Y 42 x 47-mm adaptor 020412Y Clutch oil seal punch D 15 mm

NOTE

Use the stud bolt kit to support the cover adequately when fitting the bearing on the cover.

ENG - 98

Engine

Refit the driven pulley shaft bearing with a modular

punch as shown in the figure.

NOTE IF A BEARING WITH AN ASYMMETRICAL BALL RETEN-

TION CAGE IS USED, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INTERNAL SIDE.

Specific tooling

020376Y Adapter handle 020359Y 42 x 47-mm adaptor 020363Y Crankshaft oil seal punch D 20 mm

NOTE

WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, THE CRANKCASE SHOULD, AS FAR AS POSSIBLE, BE SUPPORTED ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.

Refit the seeger ring with the opening facing the bearing opposite and fit the new oil guard levelled with

the crankcase on the pulley side.

Refitting the hub bearings

- Assemble the 3 shafts in the engine crankcase

as shown in the figure.

ENG - 99

Engine

Refitting the ub cover

- Fit a new gasket together with the centring dow-

els.

- Seal the gasket of the bleeding pipe using black

silicone sealant.

- Fit the cover making sure the bleeding pipe is in

the correct position.

- Position the shorter screw, easily recognisable

by its different colour, as shown in the figure.

- Fasten the bleeding pipe support bracket with the

lower screw.

- Fit the remaining screws and tighten the 7 screws

to the prescribed torque.

Locking torques (N*m)

Rear hub cover screws 24÷27 (17.7÷19.9 ftlb)

Flywheel cover

Removing the hub cover

- Remove the clamp fixing the hose to the cylinder.

- Remove the 10 clamps

- Remove the flywheel cover.

ENG - 100

Derbi Rambla 250 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual